3.2l - Cylinder Head, Valvetrain - Engine Code(s): Calb Audi Q5 I

Scheme 160

1. Balance Shaft Removing and installing, refer to «BALANCE SHAFT»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__balance-shaft)
2. Bolt 60 Nm To loosen and fasten, use a 8 mm drill bit as a counter-holder
3. Balance Shaft Transmission Side Can only be placed on the balance shaft in one position
4. Bearing End Bracket
5. Bolt 13 Nm
6. Balance Shaft Belt Pulley Side Can only be placed on the balance shaft in one position
7. Bolt 60 Nm To loosen and fasten, use drill 8 mm as counter-holder

CAMSHAFT TIMING CHAINS OVERVIEW

Left Camshaft Timing Chain

Scheme 161

1. Bolt 80 Nm plus an additional 90° turn Replace
2. Bolt 80 Nm plus an additional 90° turn Replace
3. Camshaft Adjuster for Exhaust Camshaft Identification "Exhaust" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
4. Camshaft Adjuster for Intake Camshaft Identification "Intake" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
5. Left Camshaft Timing Chain Remove from camshafts, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts) Before removing, mark the direction of rotation with paint Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
6. Bolt 9 Nm
7. Gliding Piece
8. Left Camshaft Timing Chain Tensioner Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
9. Drive Sprocket Mounting Bracket
10. Bolt 8 Nm plus an additional 45° turn Replace
11. Left Camshaft Timing Chain Drive Sprocket
12. Thrust Washer for Drive Sprocket
13. Bolt 6 Nm plus an additional 60° turn Replace

Right Camshaft Timing Chain

Scheme 162

1. Bolt 80 Nm plus an additional 90° turn Replace
2. Camshaft Adjuster For Exhaust Camshaft Identification "Exhaust" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
3. Bolt Replace 80 Nm plus an additional 90° turn
4. Camshaft Adjuster for Intake Camshaft Identification "Intake" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
5. Bolt 30 Nm plus an additional 90° turn Replace
6. Pivot Pin for Drive Sprocket For the right camshaft timing chain Asymmetrical version Installed position (Scheme 175)
7. Right Camshaft Timing Chain Drive Sprocket Installed position (Scheme 175)
8. Right Camshaft Timing Chain Remove from camshafts, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts) Before removing, mark the direction of rotation with paint Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
9. Thrust Washer for Drive Sprocket For the right camshaft timing chain Asymmetrical version Installed position (Scheme 175)
10. Right Camshaft Timing Chain Tensioner Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-removing-from-camshafts)
11. Gliding Piece
12. Bolt 9 Nm

CYLINDER HEAD OVERVIEW

Note. The illustration shows the cylinder bank 2 cylinder head (left).

Scheme 163

1. Cylinder Head Gasket Removing and installing, refer to «CYLINDER HEADS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-heads) Installed position: Parts number to cylinder head after replacing, change coolant and engine oil
2. Cylinder Head Removing «CYLINDER HEADS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-heads) Check for distortion (Scheme 166) Reworking dimension (Scheme 167) Installing «CYLINDER HEADS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-heads) After replacing, change coolant and engine oil
3. Bolt Tightening specification, refer to «DESCRIPTION AND OPERATION»(/audi/q5/i-2008-2012/remont/brakes-control-systems/#hydraulic-components-brake-system)
4. Vacuum Pump Removing and installing, refer to «REMOVAL AND INSTALLATION»(/audi/q5/i-2008-2012/remont/brakes-control-systems/#hydraulic-components-brake-system)
5. O-ring Replace
6. Bolt 20 Nm
7. Engine Lifting Eye
8. Camshaft Position Sensor, Intake Camshaft Cylinder bank 1 (right) Camshaft Position (CMP) Sensor -G40- Cylinder bank 2 (left) Camshaft Position (CMP) Sensor 2 -G163
9. Bolt 9 Nm
10. Bolt Tighten in 3 stages: -- Tighten to 40 Nm. -- Tighten an additional 90°. -- Tighten an additional 90°. Loosening procedure «CYLINDER HEADS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-heads) Replace Loosening procedure «CYLINDER HEADS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-heads)
11. Ignition Coil Use puller for ignition coil T40039 for removal
12. Cylinder Head Cover Removing and installing, refer to «LEFT CYLINDER HEAD COVER»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__left-cylinder-head-cover), right «RIGHT CYLINDER HEAD COVER»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__right-cylinder-head-cover)
13. Gasket Replace if damaged or leaking
14. Cover
15. Bolt Replace if the seal is damaged Tightening specifications (Scheme 164)and (Scheme 165).
16. Bolt Tightening specification, refer to «REMOVAL AND INSTALLATION»(ref-515429-S02725248432012120300000)
17. Connector Strip For ignition coils
18. Cylinder Head Cover Gasket Replace if damaged or leaking
19. Bolt 2.5 Nm
20. Solenoid Valve for Camshaft Adjustment - Exhaust Side Cylinder bank 1 (right) Exhaust camshaft control valve 1 -N318- Cylinder bank 2 (left) Camshaft Adjustment Valve 2 (exhaust) -N319
21. Solenoid Valve for Camshaft Adjustment - Intake Side Cylinder bank 1 (right) Camshaft Adjustment Valve 1 -N205- Cylinder bank 2 (left) Camshaft Adjustment Valve 2 -N208
22. O-rings Replace
23. O-ring Replace
24. Bolt 9 Nm
25. Camshaft Position Sensor, Exhaust Camshaft Cylinder bank 1 (right) Camshaft Position (CMP) Sensor 3 -G300- Cylinder bank 2 (left) Camshaft Position (CMP) Sensor 4 -G301

Scheme 164

Tighten the bolts to 9 Nm in the following sequence: -1 to 12-.

Scheme 165

Tighten the bolts to 9 Nm in the following sequence: -1 to 12-.

Scheme 166

Check the cylinder head in several places for distortion using a straight edge and a feeler gauge.

1. Maximum warp: 0.05 mm.

Scheme 167

Resurfacing cylinder head (face grinding) is only permissible to minimum dimension -a-.

1. Minimum dimension -a- = 139.20 mm.

Scheme 168

Tighten the bolt -arrow- to 9 Nm.

Scheme 169

1. Crankshaft
2. Power Take-Off Drive Chain Before removing, mark the direction of rotation with paint Removing and installing, refer to «POWER TAKE-OFF DRIVE CHAIN»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__power-take-off-drive-chain)
3. Drive Sprocket for Oil Pump Installed position: The labeled side faces the engine
4. Bolt 30 Nm plus an additional 90° turn Replace
5. Pressure Spring
6. Bolt 15 Nm plus an additional 90° turn Replace
7. Balance Shaft Chain Sprocket Installed position: The labeled side faces the transmission
8. Chain Tensioner With glide track
9. Bolt 10 Nm plus an additional 45° turn Replace

Scheme 170

1. Bolt Tightening specification and sequence (Scheme 173)
2. Crankshaft Shaft Seal, Transmission Side Removing and installing, refer to «CRANKSHAFT SEAL, TRANSMISSION SIDE»(/audi/q5/i-2008-2012/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-calb__crankshaft-seal-transmission-side)
3. Bolt Tightening specification and sequence (Scheme 173)
4. Alignment Bushing Quantity: 2
5. Bolt Tightening specification, refer to item -13- Stud Bolt in «OIL FILTER HOUSING AND OIL PRESSURE SWITCH OVERVIEW»(ref-515405-S24594246082012120300000)
6. Left Cylinder Head Gasket
7. Left Timing Chain Cover Removing and installing, refer to «LEFT AND RIGHT TIMING CHAIN COVERS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__left-and-right-timing-chain-covers)
8. Bracket For wiring harness
9. Bolt Replace Tightening specification and sequence (Scheme 171)
10. Lower Timing Chain Cover Removing and installing, refer to «LOWER TIMING CHAIN COVER»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__lower-timing-chain-cover)
11. Seals Replace
12. Bolt Tightening specification and sequence (Scheme 172)
13. Bracket for the electrical connectors
14. Bolt Replace Tightening specification and sequence (Scheme 172)
15. Right Timing Chain Cover Removing and installing, refer to «LEFT AND RIGHT TIMING CHAIN COVERS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__left-and-right-timing-chain-covers)
16. Right Cylinder Head Gasket
17. Alignment Bushing Quantity: 2
18. Bolt Tightening specification and sequence (Scheme 173)
19. Engine Speed (RPM) Sensor -G28- Removing and installing, refer to «REMOVAL AND INSTALLATION»(ref-515429-S02725248432012120300000)
20. Bolt Tightening specification, refer to «REMOVAL AND INSTALLATION»(ref-515429-S02725248432012120300000)

Scheme 171

Note. Replace the bolts for the left timing chain cover.

Scheme 172

Note. Replace the bolts for the right timing chain cover.

Scheme 173

Scheme 174

1. Guide Rail
2. Bolt 10 Nm plus an additional 90° turn Replace
3. Bolt Tightening specification, refer to item 13
4. Thrust Washer for Drive Sprocket
5. Drive Sprocket for Left Timing Chain
6. Bolt 10 Nm plus an additional 90° turn Replace
7. Power Take-Off Drive Chain Before removing, mark the direction of rotation with paint Removing and installing, refer to «TIMING MECHANISM DRIVE CHAIN»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__timing-mechanism-drive-chain)
8. Guide Rail
9. Bolt 10 Nm plus an additional 90° turn Replace
10. Bolt Tightening specification, refer to item 10
11. Mounting Bracket for Drive Sprocket For the right camshaft timing chain Asymmetrical version Installed position (Scheme 175)
12. Thrust Washer Asymmetrical version Installed position (Scheme 175)
13. Drive Sprocket for Right Timing Chain Installed position (Scheme 175)
14. Pivot Pin for Drive Sprocket Asymmetrical version Installed position (Scheme 175)
15. Bolt Tightening specification, refer to item 5
16. O-ring Replace
17. Chain Tensioner
18. Bolt 9 Nm
19. Crankshaft
20. Bolt Replace 10 Nm plus an additional 90° turn

Scheme 175

1. The alignment bushings in the right camshaft timing chain drive sprocket mounting pins -3- must engage in the holes in the thrust washer -1- and cylinder block.

2 - Right camshaft timing chain drive sprocket

4 - Bolt

VALVETRAIN OVERVIEW

Note. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked.

Note. Cylinder head for cylinder bank 2 (left) is shown in illustration.

Scheme 176

1. Sealing Plug Install with sealant
2. Cylinder Head Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-guides-checking)
3. Valve Stem Seal Replacing with the cylinder head installed, refer to «VALVE STEM SEALS, CYLINDER HEAD INSTALLED»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-stem-seals-cylinder-head-installed) Replacing with the cylinder head removed, refer to «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-stem-seals-with-cylinder-head)
4. Valve Spring Installed position (Scheme 178)
5. Hydraulic Adjusting Elements Checking, refer to «HYDRAULIC ADJUSTING ELEMENTS, CHECKING»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__hydraulic-adjusting-elements-checking) Mark the installation position with paint for reinstallation Lubricate the running surfaces before installing
6. Valve Spring Plate
7. Valve Retainers
8. Roller Rocker Lever Different versions for the intake and exhaust side, do not interchange them Check roller for easy movement Lubricate the running surfaces before installing Clip to the hydraulic adjusting element -5- with the clip -9
9. Clip Different versions for the intake and exhaust side, do not interchange them Make sure it is secure
10. Intake Camshaft With 3 camshaft sliders Do not disassemble Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-measuring-axial-play) Removing and installing, refer to «CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshafts) Measure radial clearance using Plastigage (roller rocker lever removed) Radial clearance at bearing - 24 mm diameter: 0.024 to 0.066 mm Radial clearance at bearing - 36 mm diameter: 0.032 to 0.078 mm Maximum run out: 0.04 mm
11. Bolt Replace Tightening sequence (Scheme 177)
12. Camshaft Adjuster Actuator
13. Bolt 5 Nm
14. O-ring Replace
15. Guide Frame With integrated camshaft bearings Removing and installing, refer to «CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshafts)
16. Compression Ring
17. Compression Ring
18. Exhaust Camshaft Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-measuring-axial-play) Removing and installing, refer to «CAMSHAFTS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshafts) Measure radial clearance using Plastigage (roller rocker lever removed) Radial clearance at bearing - 24 mm diameter: 0.024 to 0.066 mm Radial clearance at bearing - 36 mm diameter: 0.032 to 0.078 mm Maximum run out: 0.04 mm
19. Oil Strainer
20. Intake Valve Do not rework, only lapping is permitted Mark the installed position for installation later For the correct valve dimensions, refer to «VALVE DIMENSIONS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-dimensions) Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-guides-checking)
21. Exhaust Valve Do not rework, only lapping is permitted Mark the installed position for installation later For the correct valve dimensions, refer to «VALVE DIMENSIONS»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-dimensions) Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__valve-guides-checking)

Scheme 177

Note. The illustration shows the guide frame for the left cylinder head.

Replace the guide frame bolts.

Tighten the bolts in 3 steps in the following sequence: -1 to 21

Install bolts by hand as far as the stop.

1. The guide frame must be touching the entire contact surface of the cylinder head.

Tighten to 8 Nm.

Tighten an additional 90°.

Scheme 178

1. The tight spring coils -arrow- face toward the cylinder head.

FASTENER TIGHTENING SPECIFICATIONS

Left Timing Chain Cover, Tightening Specifications and Sequence

Note. Replace the bolts for the left timing chain cover.

Right Timing Chain Cover, Tightening Specifications and Sequence

Note. Replace the bolts for the right timing chain cover.

Lower Timing Chain Cover, Tightening Specifications and Sequence

Right Cylinder Head Cover, Tightening Specifications and Sequence

Tighten the bolts to 9 Nm in the following sequence: -1 to 12-.

Oil Dipstick Guide Tube - Tightening Specifications

Tighten the bolt -arrow- to 9 Nm.

Camshaft Guide Frame Tightening Specifications and Sequence

Note. The illustration shows the guide frame for the left cylinder head.

Replace the guide frame bolts.

Tighten the bolts in 3 steps in the following sequence: -1 to 21

Install bolts by hand as far as the stop.

1. The guide frame must be touching the entire contact surface of the cylinder head.

Tighten to 8 Nm.

Tighten an additional 90°.

VALVE DIMENSIONS

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

CAMSHAFT, MEASURING AXIAL PLAY

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge 0-3 mm VAS 6080

Procedure

Remove the camshafts. Refer to CAMSHAFTS .

Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

Secure the VW 387 with the VAS 6079 on the cylinder head as shown in the illustration.

Scheme 179

Determine the axial play.

1. Axial clearance: 0.100 to 0.191 mm.

COMPRESSION, CHECKING

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Compression Tester V.A.G 1763
3. Ignition Coil Puller T40039

Procedure

1. Engine oil temperature at least 30 °C (86 °F)
2. Battery voltage at least 12.5 V.

Remove the rear engine cover -top arrows-.

Scheme 180

Remove the strut tower brace. Refer to REMOVAL AND INSTALLATION .

Scheme 181

Remove the bolts -arrows-.

Scheme 182

Disconnect the electrical connector on the Engine Coolant Level (ECL) warning switch -F66- and lay the coolant reservoir aside with the coolant hoses -1 and 2- connected.

Note. Be careful not to bend the coolant hose -2-.

Remove the bolts -arrows- and disconnect the electrical connectors to the ignition coils on the left cylinder head.

Scheme 183

Press the electrical wiring harness down slightly.

Disconnect the electrical connector -3- to the fuel injectors on the rear of the left cylinder head.

Scheme 184

Note. Ignore -1, 2 and 4- and -arrows-.

Remove the air filter housing. Refer to REMOVAL AND INSTALLATION .

Remove the bolts -arrows- and disconnect the electrical connectors to the ignition coils on the right cylinder head.

Scheme 185

Press the electrical wiring harness to the side.

Disconnect the electrical connector -3- to the fuel injectors on the rear of the right cylinder head.

Scheme 186

Note. Ignore -1, 2 and 4- and -arrows-.

Remove all the ignition coils with the T40039.

Scheme 187

Remove the spark plugs with the 3122 B.

Check compression pressure using the V.A.G 1763.

Note. Using tester see operating instructions.

Have a second technician press the accelerator pedal down all the way while operating the starter until the pressure increase is no longer displayed on the tester.

Assembling

1. For the correct tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-head-overview) .

Assemble in reverse order of disassembling. Note the following

Install spark plugs.

Install the air filter housing. Refer to REMOVAL AND INSTALLATION .

Install the tower brace. Refer to REMOVAL AND INSTALLATION .

If the electrical connectors were disconnected and the engine was started, then the malfunctions have been stored in the engine control module. "Generate readiness code" in "Guided Functions" using the vehicle diagnostic tester.

HYDRAULIC ADJUSTING ELEMENTS, CHECKING

Note. The hydraulic adjusting elements cannot be repaired. Irregular valve noises are normal while starting the engine.

Special tools and workshop equipment required

1. Feeler gauge

Procedure

Start the engine and let it run until the coolant fan switches on once.

Increase engine speed for about 2 minutes to approximately 2500 RPM, perform a road test if necessary.

If the hydraulic adjusting elements are still loud, determine which one is faulty as follows

Remove the cylinder head cover. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Rotate the crankshaft until the cam lobes on the adjusting element that will be checked face upward. To do this, move the vehicle forward with the 4th gear engaged and the ignition switched off.

To determine the play between cam lobes and roller rocker lever, press the lever down -arrow-.

Scheme 188

If a 0.20 mm feeler gauge can slide between the cam lobes and roller rocker lever, replace the hydraulic adjusting element. Refer to CAMSHAFTS .

Final Procedures

Install the cylinder head cover. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

VALVES, CHECKING

Check valves at the stem and seating surface for traces of wear.

If there are clear traces of wear, replace valve.

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge 0-10 mm VAS 6079

Procedure

Note. If the valve is replaced during repair, use a new valve for measurement. Due to different stem diameters, only use an intake valve in the intake guide and an exhaust valve in the exhaust guide.

Place valve in valve guide.

1. Valve stem tip must seal with valve guide.

Determine tip clearance.

Scheme 189

1. Wear limit: 0.8 mm.

If the wear limit is exceeded, measure using new valves.

Replace the cylinder head if the wear limit is still exceeded.

Note. The valve guides cannot be replaced.

BALANCE SHAFT

Special tools and workshop equipment required

1. Locking Pin T40069

Removing

1. Transmission removed.

Remove the belt pulley side sealing flange. Refer to SEALING FLANGE WITH CRANKSHAFT SEAL, BELT PULLEY SIDE .

Remove lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Remove the power take-off drive chain. Refer to POWER TAKE-OFF DRIVE CHAIN .

To protect against cuts, wrap the point and the cutting edges on a 8 mm drill bit with insulating tape.

Scheme 190

Secure the balance weight -2- at rear of the engine with an 8 mm diameter drill bit -1-.

Remove the bolt -3- and remove the balance weight from the balance shaft.

Remove the bolt -2- while counter holding the balance weight using the drift and remove the balance weight -1- from the balance shaft at the front of the engine.

Scheme 191

Remove the bolts -arrows- and the balance shaft and bearing end bracket at the rear of the engine.

Scheme 192

Remove the balance shaft back out of the cylinder block.

Installing

Scheme 193

1. For the correct tightening specifications, refer to «BALANCE SHAFT OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb) .
2. Secure crankshaft -1- in "TDC" position using T40069.

Install in reverse order, paying attention to the following

Note. The balance weights can only be positioned one way on balance shaft.

Install the power take-off drive chain. Refer to POWER TAKE-OFF DRIVE CHAIN .

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

Install the belt pulley side sealing flange. Refer to SEALING FLANGE WITH CRANKSHAFT SEAL, BELT PULLEY SIDE .

CAMSHAFTS

Special tools and workshop equipment required

1. Impact Puller T10133/3 from the Tool Set T10133
2. Locating Pins T40116
3. Camshaft Clamp T40133
4. Locking Pin T40069
5. Hand drill with plastic brush attachment
6. Protective goggles
7. Sealant

Removing

Remove the camshaft timing chains from the camshafts. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

To remove the camshafts in the left cylinder head, remove the brake booster vacuum pump. Refer to REMOVAL AND INSTALLATION .

To remove the camshafts in the right cylinder head, remove the high pressure pump and pump motor housing. Refer to REMOVAL AND INSTALLATION .

Remove the bolts -arrows- and the camshaft adjuster valves.

Scheme 194

Loosen the guide frame bolts in the following sequence: -21 to 1-.

Note. The illustration shows the guide frame for the left cylinder head.

Carefully remove the guide frame and lay it on a soft surface on the workbench.

Remove the T40133.

Scheme 195

Mark the camshafts and then remove them.

Installing

1. Secure crankshaft -1- using T40069.

Note. Replace the seals and gaskets.

Using a rotating plastic brush, remove any remaining sealant from the cylinder head and guide frame.

Clean the sealing surfaces; they must be free of oil and grease.

Check the screen -arrow- for dirt and clean it if necessary.

Scheme 196

Oil running surfaces of both camshafts.

Insert the camshafts in the guide frame.

Scheme 197

1. The placement of the camshafts must be exactly within the axial bearings -arrows- of the guide frame.
2. The compression ring ends -1, 2 and 3- must face upward or downward and must never face sideways.

Rotate the guide frame with the camshafts inserted while holding them securely in the frame.

Rotate the camshafts until the threaded holes -arrows- face upward.

Scheme 198

Check if the camshafts still lie in the guide frame axial bearings.

Install the T40133 and tighten the bolts -arrows- to 25 Nm.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 2.0 mm).

Scheme 199

Rotate the guide frame again.

Apply sealant beads -4 through 8- to the clean sealing surfaces on the guide frame as shown in the illustration.

Scheme 200

1. Thickness of sealant bead: 2.0 mm.

Apply sealant beads -1 through 3- to the clean sealing surfaces on the guide frame as shown in the illustration.

1. Thickness of sealant bead: 2.5 mm.

Note. Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened.

Place the guide frame on the cylinder head.

Insert the T40116 in the guide frame and cylinder head.

Scheme 201

Note. The sealant must harden for approximately 30 minutes after installing the guide frame.

Tighten the guide frame bolts. (Scheme 177)

Clean the bores in the cylinder head for the sealing plugs; they must be free from oil and grease.

Coat the outer circumference of the sealing plug -arrow- with sealant.

Scheme 202

Drive in the sealing plugs until they are flush.

Remove the T40116 with the T10133/3.

Scheme 203

Install in reverse order of removal paying attention to the following

Install the camshaft adjustment valves. Refer to CYLINDER HEAD OVERVIEW .

Install the brake booster vacuum pump. Refer to REMOVAL AND INSTALLATION .

Install the high pressure pump motor housing and the high pressure pump. Refer to REMOVAL AND INSTALLATION .

Position the camshaft timing chain on the camshafts INSTALLING .

CAMSHAFT TIMING CHAINS

Removing

1. Transmission removed.

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

Remove the camshaft timing chains from the camshafts. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove the T40071 and left camshaft timing chain.

Scheme 204

Remove the bolts -1 and 2- and the right chain tensioner.

Scheme 205

Press the timing mechanism chain tensioner guide rail in the direction of the -arrow- and secure the chain tensioner using a T40071.

Scheme 206

Loosen the drive chain sprocket bolt -1- 1 turn.

Tilt the drive chain sprocket with the mounting pins to the side slightly and remove the right camshaft timing chain upward.

Installing

1. Tightening specification, refer to «CAMSHAFT TIMING CHAINS OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-overview) .

Note. If the tensioning element was removed from the chain tensioner, note installation position: Hole in the housing floor faces toward chain tensioner, piston faces toward tensioning rail. Replace the bolts which are being tightened with an additional turn.

Position the left camshaft timing chain according to the markings made during removal as shown in the illustration.

Press the guide rail for the left camshaft timing chain tensioner down and secure the chain tensioner using a T40071.

Guide the right camshaft timing chain on the drive sprocket mounting pins while noting the markings made during removal.

Tighten the mounting pin bolts -1-.

Remove the T40071.

Insert the chain tensioner at the right cylinder head and position the camshaft timing chain.

Fasten the bolts -1 and 2-.

Install in reverse order of removal paying attention to the following

Position the camshaft timing chain on the camshafts INSTALLING .

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Open Ring Spanner Insert, AF 24 mm V.A.G 1332/9
3. Multipoint Socket T10035
4. Counterhold Tool Touareg V10 T10172
5. Adapter T10172/2
6. Socket T40058
7. Locking Pin T40069
8. Oil Collecting and Extracting Device V.A.G 1782
9. Locking Pin T40071, quantity: 2
10. Camshaft Clamp T40133, quantity: 2

REMOVING

Note. The camshaft timing chains remain on the engine in the following description.

Remove the respective cylinder head cover. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Remove the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVERS .

Remove the noise insulation -1 and 2-. Refer to REMOVAL AND INSTALLATION .

Scheme 207

Vehicles without the After-Run Coolant Pump -V51

Remove the bolt -1- and nut -3- and the lock carrier left brace -2-.

Scheme 208

Place the V.A.G 1782 under the engine.

Scheme 209

Remove the bolts -arrows- and lay aside the oil cooler with the coolant hoses -1 and 2- connected.

Vehicles with the After-Run Coolant Pump -V51

Remove the after-run coolant pump. Refer to AFTER-RUN COOLANT PUMP -V51 and the oil cooler ENGINE OIL COOLER .

All Vehicles

Insert the T40058 guide pins as follows

Scheme 210

1. The large diameter -arrow 1- faces the engine.
2. The small diameter -arrow 2- faces the adapter.

Turn the crankshaft in the direction of engine rotation -arrow- to "TDC" using the T40058.

Scheme 211

Remove the locking bolt -arrow- for the "TDC" marking from the cylinder block.

Scheme 212

Note. The crankshaft locating hole is difficult to find when the engine is installed. Rotate the engine until the small notch -1- on the vibration damper aligns at the left of the housing separation point -2- between the cylinder block and the guide frame. This makes it easier to install the T40069. The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the T40069.

1. The threaded holes -arrows- in the camshafts must face upward.

Install the T40069 in the hole and tighten to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.

Install the T40133 in both cylinder heads and tighten the bolts -arrows- to 25 Nm.

Note. The illustration shows the left cylinder head.

Press the left camshaft timing chain tensioner guide rails in as far as the stop using a screwdriver -1- and secure the chain tensioner with a T40071.

Scheme 213

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Press the right camshaft timing chain tensioner guide rails in as far as the stop using a screwdriver -1- and secure the chain tensioner with a T40071.

Scheme 214

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Scheme 215

To counterhold at the affected camshaft adjuster, position the T10172 with the T10172/2 and loosen using the T10035.

Mark the installation position of the camshaft adjuster with paint for installation later.

Scheme 216

Remove bolts -1 and 2- on the left cylinder head and remove both camshaft adjusters.

Mark the installation position of the camshaft adjuster with paint for installation later.

Remove the bolts -1 and 2- on the right cylinder head and remove both camshaft adjusters.

Scheme 217

INSTALLING

1. For the correct tightening specifications, refer to «CAMSHAFT TIMING CHAINS OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__camshaft-timing-chains-overview) .

Note. Replace the bolts which are being tightened with an additional turn. Replace the O-ring for the Top Dead Center (TDC) marking locking bolt.

1. Drive chain for timing mechanism installed. Refer to «TIMING MECHANISM DRIVE CHAIN»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__timing-mechanism-drive-chain) .
2. Secure the crankshaft in the "TDC" position using T40069.

1. T40133 mounted on both cylinder heads and fastened to 25 Nm -arrows-.

Note. The illustration shows the left cylinder head.

Scheme 218

Note. Reinstall camshaft adjuster on the left cylinder head according to the mark applied during removal.

Position the left camshaft timing chain on the drive sprocket and the camshaft adjuster and loosely install bolts -1 and 2-.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

Remove the T40071.

Note. Reinstall camshaft adjuster on the right cylinder head according to the mark applied during removal.

Position the right camshaft timing chain on the drive sprocket and the camshaft adjuster and loosely install bolts -1 and 2-.

1. Both camshaft adjusters must be able to still be rotated on the camshaft and must not tip.

Remove the T40071.

Position the T10172 with the T10172/2 on the left intake camshaft adjuster.

Have a second technician hold the camshaft timing chain tensioned by pressing the counter hold tool in the direction of the -arrow-.

Tighten the bolts as follows while the camshaft adjuster is still held under tension.

Position the T10172 with the T10172/2 on the right exhaust camshaft adjuster.

Scheme 219

Have a second technician hold the camshaft timing chain tensioned by pressing the counter hold tool in the direction of the -arrow-.

Tighten the bolts as follows while the camshaft adjuster is still held under tension.

Remove the T40133 on both cylinder heads -arrows-.

Note. The illustration shows the left cylinder head.

Tighten the camshaft adjuster bolts on the left cylinder head as follows

Scheme 220

Tighten the camshaft adjuster bolts on the right cylinder head as follows

Scheme 221

Remove the T40069.

Using the T40058, turn the crankshaft two turns in the direction of engine rotation -arrow- until it is back at "TDC".

Note. If it is accidentally rotated beyond "TDC", rotate it back approximately 30° and set it to "TDC" again.

1. The threaded holes -arrows- in the camshafts must face upward.

Install the T40133 in both cylinder heads and tighten the bolts -arrows- to 25 Nm.

Install the T40069 directly in the hole.

1. The T40069 must engage in the locating hole of the crankshaft -1-, otherwise repeat the adjustment.

Remove the camshaft locating pins on both cylinder heads.

Remove the T40069.

Install in reverse order of removal paying attention to the following

Install the "TDC" marking locking bolt. (Scheme 225)

Install the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVERS .

Install the cylinder head covers. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Install the oil cooler. Refer to ENGINE OIL COOLER .

Install after-run coolant pump -V51-. Refer to AFTER-RUN COOLANT PUMP -V51 .

Install the lock carrier brace. Refer to REMOVAL AND INSTALLATION .

Install the noise insulation. Refer to REMOVAL AND INSTALLATION .

CYLINDER HEADS

Special tools and workshop equipment required

1. Spanner Wrench 3212
2. Socket T40058
3. Locking Pin T40069
4. Camshaft Clamp 40133

1. Engine installed.

Note. The following information describes how to remove both cylinder heads at the same time. If only one cylinder head will be removed, follow the applicable instructions in the following description.

Reduce fuel pressure in high pressure area. Refer to GENERAL INFORMATION .

Remove the upper coolant pipe. Refer to UPPER COOLANT PIPE .

Remove ribbed belt. Refer to RIBBED BELT .

Remove the lower section of the intake manifold. Refer to REMOVAL AND INSTALLATION .

Scheme 222

Disconnect the electrical connectors on the fuel injectors.

Remove the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVERS .

Remove the bolts -arrows- for the coolant pump ribbed belt pulley for power steering pump using a 3212 to counter hold.

Scheme 223

Remove the bolts -1 and 2- and lay the power steering pump to the side.

Scheme 224

Note. Ignore -3- and -arrow-.

Disconnect electrical connector -3- for Engine Coolant Temperature (ECT) Sensor -G62-.

Scheme 225

Remove the bolts -1, 2, 4 and 5- on the front coolant pipe.

Note. Ignore -arrows-.

Remove the nuts -arrows- and the high pressure line protective plate -1-.

Scheme 226

Remove the threaded connection -2- and move the fuel supply line to the side.

Scheme 227

Disconnect the connectors -1 and 6-.

Note. Ignore -3, 4, 5 and arrows-.

Disconnect the right and left electrical connectors -arrows- on the camshaft adjuster actuators.

Scheme 228

Remove the bolts -1 and 2- and free up the electrical wiring harness.

Remove the cylinder head cover. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Disconnect the electrical connector -3- on the Camshaft Position (CMP) sensor -G40-.

Scheme 229

Remove the Ground (GND) wire bolt -4-.

Note. Ignore -1, 2 and 5-.

Remove the bolts -arrows- and the bracket for the left connectors.

Note. Ignore -1 to 4-.

Remove the bolts -arrows- and the bracket for the right connectors.

Note. Ignore -1 to 4-.

Remove the bolt -arrow- and remove the oil dipstick with the guide tube.

Open the clamp and remove the vacuum hose form the vacuum pump -arrow-.

Scheme 230

Free up vacuum hose.

Remove the bolts -arrows- on the rear of the cylinder head.

Scheme 231

1. Left cylinder head: 3 bolts.
2. Right cylinder head: 4 bolts.

Note. The cams on the intake camshaft partially restrict access to the cylinder head bolts, such as bolts -1 and 2- shown in this example.. The slider on the camshaft must be pressed in the direction of -arrow A- using a plastic wedge to remove the bolt -1-. The slider on the camshaft must be pressed in the direction of -arrow B- using a plastic wedge to remove the bolt -2-.

Insert the T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. The small diameter -arrow 2- faces the adapter.

Rotate the crankshaft in the direction of engine rotation -arrow- using the T40058 until the camshaft position shown in the following illustration is reached.

Scheme 232

1. The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine as shown in the illustration.

Left Cylinder Head

Slide the unloaded camshaft slider -B- as far as the stop in the direction of the -arrow-.

Scheme 233

Right Cylinder Head

Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Scheme 234

Continuation for Both Cylinder Heads

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the T40058.

Scheme 235

1. The threaded holes -arrows- in the camshafts must face upward.

Left Cylinder Head

Remove the bolt -1-.

Scheme 236

Right Cylinder Head

Remove the bolt -2-.

Scheme 237

Continuation for Both Cylinder Heads

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the T40058.

1. The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine.

Left Cylinder Head

Slide the unloaded camshaft sliders -B and C- as far as the stop in the direction of the -arrow-.

Scheme 238

Right Cylinder Head

Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Scheme 239

Continuation for Both Cylinder Heads

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the T40058.

1. The threaded holes -arrows- in the camshafts must face upward.

Remove the camshaft timing chains from the camshafts. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Left Cylinder Head

Remove the bolts -3 through 9- while sliding the unloaded camshaft slider -A- accordingly.

Scheme 240

Remove the cylinder head.

Right Cylinder Head

Remove the bolts -10 through 16- while sliding the unloaded camshaft sliders -D and E- accordingly.

Scheme 241

Remove the cylinder head.

1. For the correct tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb__cylinder-head-overview) .

Note. Replace the bolts which are being tightened with an additional turn. Replace self-locking nuts, sealing rings, seals and O-rings. Note different sealant for cylinder head sealing surfaces and bolts. If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover. Secure all hose connections with hose clamps of the same type as those equipped by the factory. The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

Before installing the cylinder head, set the crankshaft and camshafts to "TDC" and install the T40133 on both cylinder heads and tighten to 25 Nm -arrows-.

Scheme 242

1. The T40133 is correctly positioned when the holes for the cylinder head bolts remain free.

1. T40069 must be screwed into the crankshaft.

Set cylinder head gasket in place.

Scheme 243

1. Pay close attention to centering pins -arrows- in cylinder block.
2. Cylinder head seal installation position: Identification "oben" (top) or the cylinder head part number.

Position the cylinder head.

Left Cylinder Head

Insert the bolts -1 through 7- while sliding the unloaded camshaft slider -A- accordingly.

Scheme 244

Tighten the bolts in 3 steps following the sequence -1 to 7-. Refer to CYLINDER HEAD OVERVIEW .

Right Cylinder Head

Scheme 245

Insert the bolts -8 through 14- while sliding the unloaded camshaft sliders -D and E- accordingly.

Tighten the bolts in 3 steps following the sequence -8 to 14-, refer to item 10 .

Continuation for Both Cylinder Heads

Position the camshaft timing chain on the camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove the T40133 and the T40069.

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the T40058.

1. The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine.

Left Cylinder Head

Slide the unloaded camshaft sliders -B and C- as far as the stop in the direction of the -arrow-.

Scheme 246

Right Cylinder Head

Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Continuation for Both Cylinder Heads

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the T40058.

1. The threaded holes -arrows- in the camshafts must face upward.

Left Cylinder Head

Insert the bolt -15- and tighten it in 3 steps CYLINDER HEAD OVERVIEW .

Scheme 247

Right Cylinder Head

Insert the bolt -16- and tighten it in 3 steps CYLINDER HEAD OVERVIEW .

Scheme 248

Continuation for Both Cylinder Heads

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the T40058.

1. The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine.

Left Cylinder Head

Slide the unloaded camshaft slider -B- as far as the stop in the direction of the -arrow-.

Scheme 249

Right Cylinder Head

Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Continuation for Both Cylinder Heads

Tighten the bolts -arrows-.

1. Left cylinder head: 3 bolts.
2. Right cylinder head: 4 bolts.

Note. Do not tighten the cylinder head bolts.

Install in reverse order of removal paying attention to the following

Install oil dipstick guide tube. (Scheme 168)

Position the camshaft timing chain on the camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS Installing .

Install the cylinder head cover. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Install front coolant pipe. Refer to FRONT COOLANT PIPE .

Install power steering pump. Refer to REMOVAL AND INSTALLATION .

Install the front muffler. Refer to FRONT MUFFLER .

Install the fuel supply line and the lower section of the intake manifold. Refer to REMOVAL AND INSTALLATION .

Install the ribbed belt. Refer to RIBBED BELT .

Install the upper coolant pipe. Refer to UPPER COOLANT PIPE .

Change engine oil.

Replace the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

LEFT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Ignition Coil Puller T40039

Removing

Remove the engine covers -arrows-.

Remove the bolts -arrows-.

Disconnect the electrical connector on the Engine Coolant Level (ECL) warning switch -F66- and lay the coolant reservoir aside with the coolant hoses -1 and 2- connected.

Note. Be careful not to bend the coolant hose -2-.

Remove the bolts -arrows- and disconnect the electrical connectors to the ignition coils on the left cylinder head.

Scheme 250

Disconnect the electrical connector -1- on the Camshaft Position (CMP) sensor 2 -G163- and -4- on the CMP sensor 4 -G301-.

Press the connector release catches and disconnect the connector -3- on the camshaft adjustment valve 2 -N208- and exhaust camshaft adjustment valve 2 -N319-.

Remove the ground wire bolt -5-.

Move the electrical wiring harness to the side.

Note. Ignore -2-.

Remove the ignition coils with the T40039.

Remove the bolts in the following sequence -12 to 1- and lay the left cylinder head aside with the crankcase ventilation hose -arrow- connected.

Installing

Install in reverse order, paying attention to the following

Note. Replace the O-ring. Replace the cylinder head seal if it is damaged. Replace the cylinder head cover bolts when replacing the damaged seal.

Clean the sealing surfaces; they must be free of oil and grease.

Tighten the left cylinder head cover bolts. (Scheme 164)

LEFT AND RIGHT TIMING CHAIN COVERS

Special tools and workshop equipment required

1. Hand drill with plastic brush attachment
2. Protective goggles
3. Sealant

Note. When installing, bring all the cable ties back to the same positions.

Remove the rear engine cover -top arrows-.

Remove the affected secondary air injection combination valve. Refer to LEFT SECONDARY AIR COMBINATION VALVE , RIGHT SECONDARY AIR COMBINATION VALVE .

Left Timing Chain Cover

Remove the electrical connectors -1 through 4- from the bracket and press to the side.

Note. Ignore -arrows-.

Free up electrical wires.

Remove the bolts -1 through 8- and remove the left timing chain cover.

Right Timing Chain Cover

Remove the electrical connectors -1 through 4- from the bracket and press to the side.

Note. Ignore -arrows-.

Remove the bolts -1 through 8- and remove the right timing chain cover.

Remove the sealant residue on the covers for the timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.

Scheme 251

Clean the sealing surfaces; they must be free of oil and grease.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 2 mm).

Apply the sealant bead -arrow- to the clean sealing surfaces on the left timing chain cover as shown in the illustration.

Scheme 252

1. Thickness of sealant bead: 2.5 mm.

Note. Covers for the timing chain must be installed within 5 minutes after applying the sealant.

Position the left timing chain cover and tighten the bolts. (Scheme 171)

Apply the sealant bead -arrow- to the clean sealing surfaces on the right timing chain cover as shown in the illustration.

1. Thickness of sealant bead: 2.5 mm.

Position the right timing chain cover and tighten the bolts. (Scheme 172)

Install in reverse order of removal paying attention to the following

Note. Secure all the hose connections with the hose clamps of the same type as those equipped by the factory.

Install the secondary air injection combination valve. Refer to LEFT SECONDARY AIR COMBINATION VALVE , RIGHT SECONDARY AIR COMBINATION VALVE .

LOWER TIMING CHAIN COVER

Special tools and workshop equipment required

1. Hand drill with plastic brush attachment
2. Protective goggles
3. Sealant

Removing

1. Transmission removed.

Note. When installing, bring all cable ties back to same positions.

Disconnect the battery. Refer to REMOVAL AND INSTALLATION .

Remove the drive plate. Refer to DRIVE PLATE .

Remove the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVERS .

Remove the oil filter housing. Refer to OIL FILTER HOUSING .

Remove generator. Refer to REMOVAL AND INSTALLATION .

Remove the left and right bolts -arrows- and the electrical connector bracket.

Note. Ignore -1 to 4-.

Disconnect the starter electrical connector -3- by sliding the retainer back and pressing the release down.

Scheme 253

Remove the electrical wire nut -2- and starter.

Note. Ignore -1 and 4-.

Remove the bolts -arrows-.

Remove the bolts -1 through 10- and remove the lower timing chain cover.

Press the transmission side of the crankshaft shaft seal out of the lower timing chain cover.

Installing

1. For the correct tightening specifications (Scheme 173)

Note. Replace seals, gaskets and O-rings.

Remove the upper right alignment bushing from the cylinder block.

Grind the alignment bushing down at an angle as shown in the illustration.

Scheme 254

1. Dimension -x- = 6.5 mm.
2. Dimension -y- = 8 mm.

Insert the alignment bushing in the cylinder block so the angled side faces up.

Note. Because of the chamfer, the lower timing chain cover can be positioned more easily when the cylinder head is installed.

Remove the sealant residue on the cover for the timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.

Clean the sealing surfaces; they must be free of oil and grease.

Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

Clean old sealant out of the holes -arrow- in the cylinder head seals.

Scheme 255

Note. With cylinder head installed, holes in cylinder head seal are only half visible.

Note. A kinked cylinder head seal must be replaced.

Bend the end of the cylinder head seals down slightly -arrows- until the upper sealing surface of the seals and the cylinder head can be cleaned.

Scheme 256

Clean the upper and lower cylinder head gaskets; they must free from oil and grease.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 2 mm).

Note. The sealant must be applied to several places on the engine, as described in the following.

Lightly coat the top and bottom cylinder head seal sealing surfaces with lubricant by bending the seals down slightly again -arrows-.

Use a flat object such as a feeler gauge to coat the surface between the cylinder head and seal.

Fill the cleaned cylinder head seal holes -arrow- with sealant.

Apply sealant beads -1 through 4- on the clean lower timing chain cover sealing surfaces as shown in the illustration.

Scheme 257

1. The groove of sealing surface must be completely filled with sealant.
2. The sealant beads must be 1.5 to 2.0 mm above the sealing surface.
3. The sealant bead -2- must be drawn through as shown in the illustration even though the groove is intermittent.

Note. The sealant only needs to cure for approximately 5 minutes after applying.

Insert the seals -arrows- in the grooves on the lower timing chain cover.

Position the lower timing chain cover, guiding it diagonally from below to the sealing surface on the cylinder block and cylinder head.

When positioning, ensure the cylinder head seals are not damaged.

Tighten the bolts for the lower timing chain cover. (Scheme 173)

Install in reverse order of removal paying attention to the following

Install starter. Refer to REMOVAL AND INSTALLATION .

Install generator. Refer to REMOVAL AND INSTALLATION .

Install the oil filter housing. Refer to OIL FILTER HOUSING .

Install the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVERS Installing .

Install the transmission-side crankshaft shaft seal. Refer to CRANKSHAFT SEAL, TRANSMISSION SIDE .

Installing the drive plate. Refer to DRIVE PLATE .

POWER TAKE-OFF DRIVE CHAIN

Special tools and workshop equipment required

1. Key T40049
2. Locking Pin T40071
3. Locking Pin T40069
4. 8 mm drill bit

Removing

1. Transmission removed.

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

Install the T40049 at the rear of the crankshaft using two old drive plate bolts -arrows-.

Scheme 258

Remove the locking bolt -arrow- for the Top Dead Center (TDC) marking from the cylinder block.

Rotate the crankshaft in the direction of engine rotation to "TDC".

Note. The crankshaft locating hole is difficult to find when the engine is installed. Rotate the engine until the small notch -1- on the vibration damper aligns at the left of the housing separation point -2- between the cylinder block and the guide frame. This makes it easier to install the T40069. The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the T40069.

Install the T40069 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and slightly to completely center the bolt, if necessary.

Press the chain tensioner guide rail in direction of -arrow- and secure chain tensioner using a T40071.

Scheme 259

Remove the bolts -3- and the balance shaft chain sprocket.

Remove the bolts -1 and 2- and the chain tensioner with the drive chain.

Installing

1. For the correct tightening specifications, refer to «POWER TAKE-OFF DRIVE CHAIN OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb) .
2. Secure crankshaft -1- in "TDC" position using T40069.

Note. Replace the O-ring for the "TDC" marking locking bolt.

Install the chain tensioner with the drive chain and the balance shaft chain sprocket.

Scheme 260

To protect against cuts, wrap the point and the cutting edges on a 8 mm drill bit with insulating tape.

Secure the balance shaft in the "TDC" position using an 8 mm diameter drill bit -2-.

1. The slots in the balance shaft sprocket must be at the middle position in relation to the threaded holes of the balance shaft. If necessary, adjust chain by one tooth.

Tighten the chain tensioner bolts.

Loosely install the chain sprocket bolts -1 and 3-.

1. It must still be possible to rotate the chain sprocket on the balance shaft and it must not tip.

Remove the T40071 to release the chain tensioner.

Press against the chain tensioner guide rail -arrow- using a screwdriver while tightening the chain sprocket bolts -1 and 3-.

Remove the drill bit -2- from the balance shaft.

Install in reverse order of removal paying attention to the following

Install the "TDC" marking locking bolt. Refer to. (Scheme 225).

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

RIGHT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Ignition Coil Puller T40039

Removing

Remove the engine covers -arrows-.

Remove the air filter housing. Refer to REMOVAL AND INSTALLATION .

Remove the bolts -arrows- and disconnect the electrical connectors to the ignition coils on the right cylinder head.

Disconnect the electrical connector -5- on the Camshaft Position (CMP) sensor 3 -G300-.

Press the connector release catches and disconnect the connector -1- on the camshaft adjustment valve 1 -N205- and camshaft adjustment valve 1 (exhaust) -N318-.

Press the electrical wiring harness to the side.

Note. Ignore -2, 3 and 4-.

Remove the ignition coils with the T40039.

Remove the bolts in the following sequence -12 to 1- and lay the right cylinder head aside with the crankcase ventilation hose -arrow- connected.

Installing

Install in reverse order, paying attention to the following

Note. Replace the O-ring. Replace the cylinder head seal if it is damaged. Replace the cylinder head cover bolts when replacing the damaged seal.

Clean the sealing surfaces; they must be free of oil and grease.

Tighten the right cylinder head cover bolts. (Scheme 165)

Install the air filter housing. Refer to REMOVAL AND INSTALLATION .

TIMING MECHANISM DRIVE CHAIN

Special tools and workshop equipment required

1. Locking pin T40071

Removing

1. Transmission removed.

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

Remove the camshaft timing chains from the camshafts. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove the power take-off drive chain. Refer to POWER TAKE-OFF DRIVE CHAIN .

Press the drive chain tensioner guide rail in the direction of the -arrow- and secure the chain tensioner with a T40071.

Scheme 261

Remove the bolts -1- and the guide rail.

Remove the bolts -2- and the chain tensioner.

Remove the timing mechanism drive chain.

Installing

1. For the correct tightening specifications, refer to «TIMING MECHANISM DRIVE CHAIN OVERVIEW»(/audi/q5/i-2008-2012/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-calb) .

Install in reverse order, paying attention to the following

Note. Replace the bolts which are being tightened with an additional turn.

Position the timing mechanism drive chain according to the markings made on the drive chain sprockets during removal.

Install the guide rail and tighten the bolts -1-.

Install the chain tensioner and tighten the bolts -2-.

Press the drive chain tensioner guide rail in direction of -arrow- and pull T40071 out of the chain tensioner.

Install the power take-off drive chain. Refer to POWER TAKE-OFF DRIVE CHAIN .

Position the camshaft timing chain on the camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

VALVE STEM SEALS, CYLINDER HEAD INSTALLED

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate for FSI Engine VAS 5161/19B
5. Pressure Fork VAS 5161/2
6. Knurled Screws VAS 5161/12
7. Drift VAS 5161/3
8. Installation Fork VAS 5161/5
9. Engaging Device VAS 5161/6
10. Installation Cartridge VAS 5161/8
11. Valve Retainer Inserting Tool VAS 5161/18
12. Adapter T40012

Removing

Remove the camshafts. Refer to CAMSHAFTS .

Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

Remove the spark plugs with 3122 B.

Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

Position the VAS 5161/3 on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Scheme 262

Place the VAS 5161/19B from the VAS 5161 on the cylinder head.

Scheme 263

Secure the guide plate with the VAS 5161/12.

Install T40012 with the sealing ring in respective spark plug thread and hand tighten.

Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

1. Minimum pressure: 6 bar (87 psi) positive pressure.

Install VAS 5161/6 with VAS 5161/5 in guide plate.

Scheme 264

Slide VAS 5161/8 in guide plate.

Engage VAS 5161/2 on engaging device and press installation cartridge down.

At the same time, rotate installation cartridge knurled screw right until points engage in the valve retainers.

Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the installation cartridge.

Release the pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

Remove the valve spring and the valve spring plate.

Remove the valve stem seal with the 3364.

Scheme 265

If the 3364 cannot be used, on several valve stem seals due to restricted clearance, proceed as follows

Scheme 266

Drive out the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

Position the lower part of the 3364 on the valve stem seal.

Scheme 267

Secure the puller with a drift or cotter pin drive -1- as shown in the illustration.

Position the valve lever on the puller and remove the valve stem seal -arrow-.

Scheme 268

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with 3365.

Remove plastic sleeve again.

When the valve retainers were removed from the installation cartridge, they must be inserted in the VAS 5161/18 next.

Scheme 269

1. The large diameter of the valve retainers point upward.

Press installation cartridge from above onto valve retainer inserting tool and capture keepers.

Insert the valve spring and the valve spring plate. (Scheme 178)

Install the guide plate on the cylinder head.

Insert installation cartridge in guide plate.

Press the pressure fork down and pull the knurled screw up while turning left and right. This inserts the valve retainers.

Release the pressure fork with the knurled screw still raised.

Repeat the procedure on each valve.

Installing

Installing is in reverse order of removing. Note the following

Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

Install the camshafts. Refer to CAMSHAFTS .

Install spark plugs.

VALVE STEM SEALS WITH CYLINDER HEAD REMOVED

Special tools and workshop equipment required

1. Valve Seal Removal Tool 3364
2. Valve Stem Seal Driver 3365
3. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate for FSI Engine VAS 5161/19B
4. Pressure Fork VAS 5161/2
5. Drift VAS 5161/3
6. Installation Fork VAS 5161/5
7. Engaging Device VAS 5161/6
8. Installation Cartridge VAS 5161/8
9. Knurled Screws VAS 5161/12
10. Valve Retainer Inserting Tool VAS 5161/18
11. Engine and Transmission Holder VAS 6095
12. Cylinder Head Tensioning Device VAS 6419

Removing

Remove the camshafts. Refer to CAMSHAFTS .

Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

Mount the VAS 6419 into the VAS 6095.

Scheme 270

Tension the cylinder head on the cylinder head tensioning device, as illustrated.

Connect the cylinder head tensioning device to the compressed air.

Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seals that will be removed.

Let enough compressed air flow into the air cushion until it contacts the valve plate.

Position the VAS 5161/3 on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Place the VAS 5161/19B from the VAS 5161 on the cylinder head.

Scheme 271

Secure the guide plate with the VAS 5161/12.

Install VAS 5161/6 with VAS 5161/5 in guide plate.

Scheme 272

Slide VAS 5161/8 in guide plate.

Engage VAS 5161/2 on engaging device and press installation cartridge down.

At the same time, rotate installation cartridge knurled screw right until points engage in valve retainers.

Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the installation cartridge.

Release the pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

Remove the valve spring and the valve spring plate.

Remove the valve stem seal with the 3364.

Position the valve lever on the puller and remove the valve stem seal -arrow-.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with 3365.

Remove plastic sleeve again.

When the valve retainers were removed from the installation cartridge, they must be inserted in the VAS 5161/18 next.

1. The large diameter of the valve retainers point upward.

Press installation cartridge from above onto valve retainer inserting tool and capture keepers.

Insert the valve spring and the valve spring plate. (Scheme 178)

Install the guide plate on the cylinder head.

Insert installation cartridge in guide plate.

Press the pressure fork down and pull the knurled screw up while turning left and right. This inserts the valve retainers.

Release the pressure fork with the knurled screw still raised.

Repeat the procedure on each valve.

Installing

Assemble in reverse order of disassembling. Note the following

Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

Install the camshafts. Refer to CAMSHAFTS .

Scheme 273

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Open Ring Spanner Insert, AF 24 mm V.A.G 1332/9
3. Multipoint Socket T10035
4. Counterhold Tool Touareg V10 T10172
5. Socket T40058
6. Locking Pin T40069

Scheme 274

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate for FSI Engine VAS 5161/19B
5. Adapter T40012

Scheme 275

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Compression Tester V.A.G 1763
3. Ignition Coil Puller T40039

Special tools and workshop equipment required

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

1. Spanner Wrench 3212
2. Impact Puller T10133/3 from the Tool Set T10133
3. Key T40049
4. Locking Pin T40071, quantity: 2
5. Locating Pins T40116
6. Camshaft Clamp T40133, quantity: 2
7. Oil Collecting and Extracting Device V.A.G 1782
8. Dial Gauge 0-10 mm VAS 6079
9. Dial Gauge 0-3 mm VAS 6080
10. Engine and Transmission Holder VAS 6095
11. Dial Gauge Holder VW 387
12. Not illustrated
13. Adapter T10172/2
14. Drift VAS 5161/3
15. Pressure Fork VAS 5161/2
16. Installation Fork VAS 5161/5
17. Engaging Device VAS 5161/6
18. Installation Cartridge VAS 5161/8
19. Knurled Screws VAS 5161/12
20. Valve Retainer Inserting Tool VAS 5161/18 Cylinder Head Tensioning Device VAS 6419

See also:
• DESCRIPTION AND OPERATION
• CRANKSHAFT SEAL, TRANSMISSION SIDE
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• SEALING FLANGE WITH CRANKSHAFT SEAL, BELT PULLEY SIDE
• REMOVAL AND INSTALLATION
• AFTER-RUN COOLANT PUMP -V51
• REMOVAL AND INSTALLATION
• UPPER COOLANT PIPE
• RIBBED BELT
• FRONT COOLANT PIPE
• REMOVAL AND INSTALLATION
• FRONT MUFFLER
• COOLING SYSTEM, DRAINING AND FILLING
• LEFT SECONDARY AIR COMBINATION VALVE
• RIGHT SECONDARY AIR COMBINATION VALVE
• REMOVAL AND INSTALLATION
• DRIVE PLATE
• BALANCE SHAFT
• CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS
• CYLINDER HEADS
• LEFT CYLINDER HEAD COVER
• RIGHT CYLINDER HEAD COVER
• POWER TAKE-OFF DRIVE CHAIN
• LEFT AND RIGHT TIMING CHAIN COVERS
• LOWER TIMING CHAIN COVER
• TIMING MECHANISM DRIVE CHAIN
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS, CYLINDER HEAD INSTALLED
• VALVE STEM SEALS WITH CYLINDER HEAD REMOVED
• HYDRAULIC ADJUSTING ELEMENTS, CHECKING
• CAMSHAFT, MEASURING AXIAL PLAY
• CAMSHAFTS
• VALVE DIMENSIONS
• TIMING MECHANISM DRIVE CHAIN OVERVIEW
• CYLINDER HEAD OVERVIEW
• INSTALLING
• CAMSHAFT TIMING CHAINS OVERVIEW