3.0l - Cylinder Head, Valvetrain - Engine Code(s): Cata Audi Q7 4L рестайлинг

CYLINDER HEAD COVER OVERVIEW

Note. The cylinder head cover for cylinder bank 2 (left) is shown in the illustration.

Scheme 437

1. Cylinder Head Cover Gasket Replace if damaged or leaking
2. Cylinder Head Cover Removing and installing, refer to «LEFT CYLINDER HEAD COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-cylinder-head-cover) and «RIGHT CYLINDER HEAD COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-cylinder-head-cover)
3. Bolt With gasket Replace if the seal is damaged or leaking Tightening specification and sequence (Scheme 438)
4. O-ring Replace
5. Oil Filler Neck To remove, lift the tab, turn the oil filler neck to the left and remove it.
6. Seal
7. Seal Replace if damaged or leaking
8. Cap
9. Nut Tightening specifications, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
10. High-Pressure Line Note rules of cleanliness, refer to «CLEAN WORKING CONDITIONS»(/audi/q7/4l-2009-2015/remont/exhaust/#30l-general-technical-data-engine-mechanical-engine-codes-cata__clean-working-conditions) Mark the order of the injectors Do not change bent shape Installing, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
11. Fuel Return Line Note rules of cleanliness, refer to «CLEAN WORKING CONDITIONS»(/audi/q7/4l-2009-2015/remont/exhaust/#30l-general-technical-data-engine-mechanical-engine-codes-cata__clean-working-conditions)
12. O-ring Replace
13. Bolt Tightening specifications, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
14. Tensioning Bracket
15. Screw 5 Nm
16. Bracket For the electrical connectors
17. Injector Note rules of cleanliness, refer to «CLEAN WORKING CONDITIONS»(/audi/q7/4l-2009-2015/remont/exhaust/#30l-general-technical-data-engine-mechanical-engine-codes-cata__clean-working-conditions) Removing and installing, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
18. Bolt 5 Nm
19. Bracket For the electrical wiring harness
20. O-ring Replace
21. Copper Sealing Ring Replace

Scheme 438

Tighten the cylinder head cover bolts -arrows- in a diagonal sequence in stages to 9 Nm.

CYLINDER HEAD OVERVIEW

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

Scheme 439

1. Cylinder Head Gasket Removing and installing, refer to «CYLINDER HEAD»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata) Identification (Scheme 441)Installation position: Parts number to cylinder head After replacing, change coolant and engine oil
2. Bolt Tightening specifications, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
3. Bolt Tightening specifications, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
4. High Pressure Pump Toothed Belt Drive Sprocket Removing and installing, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
5. Rear Toothed Belt Guard
6. Camshaft Seal Removing and installing, refer to «CAMSHAFT SEAL»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-seal)
7. Seals Replace
8. Banjo Bolt Tightening specifications, refer to "Banjo Bolt" in numbered list under «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview)
9. Fuel Rail Note rules of cleanliness, refer to «CLEAN WORKING CONDITIONS»(/audi/q7/4l-2009-2015/remont/exhaust/#30l-general-technical-data-engine-mechanical-engine-codes-cata__clean-working-conditions) Removing and installing, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata) Do not change the angles of the high pressure lines High pressure lines, removing and installing, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
10. Bolt Tightening specifications, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
11. Coolant Pipe
12. Bolt Replace Loosening sequence «LOOSEN THE CYLINDER HEAD BOLTS IN THE FOLLOWING SEQUENCE -1 THROUGH 8»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata) Tightening specification and sequence (Scheme 442)
13. Engine Lifting Eye
14. M8 Bolts 23 Nm
15. M6 Bolt 9 Nm
16. Cylinder Head Removing and installing, refer to «CYLINDER HEAD»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata) Do not lay the cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface Check for distortion (Scheme 440)It is not permitted to re-work the cylinder heads on TDI engines After replacing, change coolant and engine oil

Scheme 440

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

1. Maximum permissible distortion: 0.1 mm

Scheme 441

1. Holes
2. Part number

Note. The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

Scheme 442

Note. Replace bolts which have been tightened to an additional torque.

Tighten the bolts in 5 steps according to the tightening sequence

TIMING CHAIN COVERS OVERVIEW

Vehicles Built through 05.10

Scheme 443

1. Crankshaft Shaft Seal, Transmission Side Removing and installing, refer to «CRANKSHAFT SEAL, TRANSMISSION SIDE»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-crankshaft-cylinder-block-engine-codes-cata__crankshaft-seal-transmission-side)
2. Lower Timing Chain Cover Removing and installing, refer to «LOWER TIMING CHAIN COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__lower-timing-chain-cover)
3. Alignment Bushing 2 pieces
4. Bolt Replace Tightening specification and sequence (Scheme 445)
5. Bolt 9 Nm
6. Cap
7. O-ring Replace
8. Bolt Replace Tightening specification and sequence (Scheme 445)
9. Left Timing Chain Cover Removing and installing, refer to «LEFT TIMING CHAIN COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-timing-chain-cover)
10. Gasket Replace
11. Bolt Replace Tightening specification and sequence (Scheme 446)
12. Bolt Tightening specifications, refer to «FASTENER TIGHTENING SPECIFICATIONS»(/audi/q7/4l-2009-2015/remont/mechanical-hydraulic/#hydraulic-components-brake-system__fastener-tightening-specifications)
13. Vacuum Pump Removing and installing, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/mechanical-hydraulic/#hydraulic-components-brake-system)
14. O-rings Replace
15. Right Timing Chain Cover Removing and installing, refer to «RIGHT TIMING CHAIN COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-timing-chain-cover)
16. Gasket Replace
17. Bolt Replace Tightening specification and sequence (Scheme 446)
18. Alignment Bushing 2 pieces
19. Sealing Piece 2 pieces
20. Bolt Tightening specification and sequence (Scheme 447)

Vehicles Built from 06.10

Scheme 444

1. Bolt Tightening specification and sequence (Scheme 447)
2. Sensor Wheel For the engine speed sensor -G28
3. Crankshaft Shaft Seal, Transmission Side Removing and installing, refer to «CRANKSHAFT SEAL, TRANSMISSION SIDE»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-crankshaft-cylinder-block-engine-codes-cata__crankshaft-seal-transmission-side)
4. Lower Timing Chain Cover Removing and installing, refer to «LOWER TIMING CHAIN COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__lower-timing-chain-cover)
5. Alignment Bushing 2 pieces
6. Bolt Replace Tightening specification and sequence (Scheme 445)
7. Bolt 9 Nm
8. Cap
9. O-ring Replace
10. Bolt Replace Tightening specification and sequence (Scheme 445)
11. Left Timing Chain Cover Removing and installing, refer to «LEFT TIMING CHAIN COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-timing-chain-cover)
12. Gasket Replace
13. Bolt Replace Tightening specification and sequence (Scheme 446)
14. Bolt Tightening specifications, refer to «FASTENER TIGHTENING SPECIFICATIONS»(/audi/q7/4l-2009-2015/remont/mechanical-hydraulic/#hydraulic-components-brake-system__fastener-tightening-specifications)
15. Vacuum Pump Removing and installing, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/mechanical-hydraulic/#hydraulic-components-brake-system)
16. O-rings Replace
17. Right Timing Chain Cover Removing and installing, refer to «RIGHT TIMING CHAIN COVER»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-timing-chain-cover)
18. Gasket Replace
19. Bolt Replace Tightening specification and sequence (Scheme 446)
20. Alignment Bushing 2 pieces
21. Sealing piece 2 pieces
22. Cover For the starter
23. Cover For the engine speed (RPM) sensor -G28
24. Bolt Tightening specifications, refer to «Ignition/Glow Plug System»(/audi/q7/4l-2009-2015/remont/ignition-system/#30l-ignitionglow-plug-system-engine-codes-cata)
25. Engine Speed (RPM) Sensor -G28- Removing and installing, refer to «Ignition/Glow Plug System»(/audi/q7/4l-2009-2015/remont/ignition-system/#30l-ignitionglow-plug-system-engine-codes-cata)

Scheme 445

Tighten bolts in 4 stages as follows

Scheme 446

Tighten bolts in 4 stages as follows

Scheme 447

Tighten the bolts in 3 steps according to the tightening sequence

CAMSHAFT TIMING CHAINS OVERVIEW

Left Camshaft Timing Chain

Scheme 448

1. Thrust Washer For drive sprocket
2. Bolt Tightening specifications, refer to item 4
3. Bolt Replace 5 Nm plus an additional 90° turn
4. Guide Rail Pay attention to the installed position
5. Bolt Replace 5 Nm plus an additional 90° turn
6. Chain Tensioner For the left camshaft control chain
7. Bolt 23 Nm
8. Camshaft Chain Sprocket For intake camshaft Installation position: The side with lettering faces forward
9. Left Camshaft Timing Chain Remove from camshafts, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-timing-chains-removing-from-camshafts) Before removing, mark the direction of rotation with paint Removing and installing, refer to «CAMSHAFT TIMING CHAINS»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-timing-chains)
10. Bolt With sleeve Replace 5 Nm plus an additional 90° turn
11. Tensioning Rail
12. Bracket For drive sprocket
13. Bolt Tightening specifications, refer to item 10
14. Drive Sprocket For the left camshaft control chain

Right Camshaft Timing Chain

Scheme 449

1. Bolt Tightening specifications, refer to item 2
2. Mounting Pin For drive sprocket
3. Right Camshaft Timing Chain Remove from camshafts «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-timing-chains-removing-from-camshafts) Before removing, mark the direction of rotation with paint Removing and installing, refer to «CAMSHAFT TIMING CHAINS»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-timing-chains)
4. Camshaft Chain Sprocket For intake camshaft Installation position: The side with lettering faces forward
5. Bolt 23 Nm
6. Chain Tensioner For the right camshaft timing chain
7. Bolt Replace 5 Nm plus an additional 90° turn
8. Thrust washer For drive sprocket
9. Drive Sprocket For the right camshaft timing chain

Scheme 450

1. Pivot Pin for Drive Sprocket
2. Bolt 45 Nm
3. Bolt Replace 5 Nm plus an additional 90° turn
4. Bolt Replace 5 Nm plus an additional 90° turn
5. Thrust Washer for Drive Sprocket
6. Drive Sprocket for Left Timing Chain
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/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__timing-mechanism-drive-chain)
8. Guide Rail Pay attention to the installed position
9. Bolt Replace 5 Nm plus an additional 90° turn
10. Bolt Replace 5 Nm plus an additional 90° turn
11. Mounting Bracket for Drive Sprocket
12. Thrust Washer
13. Drive Sprocket for Right Timing Chain
14. Mounting Pin 12 Nm Insert with locking compound; Locking compound .
15. O-ring Replace
16. Chain Tensioner
17. Bolt 12 Nm
18. Tensioning Rail
19. Crankshaft With chain sprockets
20. Guide Rail
21. Mounting Pin 12 Nm Insert with locking compound; Locking compound .

Scheme 451

1. Power Take-Off Drive Chain Removing and installing, refer to «POWER TAKE-OFF DRIVE CHAIN»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__power-take-off-drive-chain)
2. Drive Sprocket for Oil Pump Installation position: The labeled side faces the engine
3. Bolt Tightening specifications, refer to "Bolt" in numbered list under «OIL PUMP AND LOWER OIL PAN OVERVIEW»(/audi/q7/4l-2009-2015/remont/lubrication-system/#30l-lubrication-engine-codes-cata__oil-pump-and-lower-oil-pan)
4. Thrust Washer
5. Spring
6. Crankshaft
7. Bolt 23 Nm
8. Balance Shaft Chain Sprocket Installation position: The labeled side faces the transmission
9. Bolt 9 Nm
10. Chain Tensioner With glide track
11. Gasket Replace

Scheme 452

1. Friction Bearing
2. Bolt 60 Nm When loosening or tightening, us the diesel injection pump locking pin 3359 as a counterhold tool
3. Balance Shaft Transmission Side
4. Bolt 9 Nm Insert with locking compound; Locking compound .
5. Bearing End Bracket
6. Balance Shaft Belt Pulley Side
7. Bolt 60 Nm When loosening or tightening, us the diesel injection pump locking pin 3359 as a counterhold tool
8. Friction Bearing
9. Balance Shaft Removing and installing, refer to «BALANCE SHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__balance-shaft)

VALVETRAIN OVERVIEW

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

Scheme 453

1. Valve Do not reface, only lapping is permitted Mark the installed position for installation later Checking, refer to «VALVES, CHECKING»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__valves-checking) For the correct valve dimensions, refer to «VALVE DIMENSIONS»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__valve-dimensions)
2. Cylinder Head Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__valve-guides-checking) The valve seat may not be reworked due to a close tolerances.
3. Valve Stem Seal Replace, refer to «VALVE STEM SEALS, CYLINDER HEAD INSTALLED»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__valve-stem-seals-cylinder-head-installed) and «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__valve-stem-seals-with-cylinder-head)
4. Valve Spring
5. Valve Spring Plate
6. Valve Retainers
7. Camshaft Seal Removing and installing, refer to «CAMSHAFT SEAL»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-seal).
8. Bolt Tightening specifications and sequence (Scheme 454), (Scheme 455)
9. Nut Tightening specifications and sequence (Scheme 454), (Scheme 455)
10. Guide Frame With integrated camshaft bearings Removing and installing, refer to «LEFT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-cylinder-head-camshaft) and «RIGHT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-cylinder-head-camshaft)
11. Intake Camshaft Removing and installing, refer to «LEFT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-cylinder-head-camshaft) and «RIGHT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-cylinder-head-camshaft) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-measuring-axial-play) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-measuring-radial-play) Maximum run out: 0.01 mm
12. Exhaust Camshaft Removing and installing, refer to «LEFT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-cylinder-head-camshaft) and «RIGHT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-cylinder-head-camshaft) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-measuring-axial-play) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-measuring-radial-play) Maximum run out: 0.01 mm
13. Roller Rocker Lever Removing and installing, refer to «LEFT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__left-cylinder-head-camshaft), «RIGHT CYLINDER HEAD CAMSHAFT»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__right-cylinder-head-camshaft) Mark the installed position for installation later Check roller for easy movement Lubricate the running surfaces before installing
14. Hydraulic Adjusting Elements Mark the installed position for installation later Checking, refer to «HYDRAULIC ADJUSTING ELEMENTS, CHECKING»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__hydraulic-adjusting-elements-checking) Lubricate the running surfaces before installing
15. Pressure Relief Valve 1.0 Bar 25 Nm For the lubricating points in the cylinder head

Scheme 454

Tighten the bolts and nuts in 2 steps in the sequence shown

Scheme 455

Tighten the bolts and nuts in 2 steps in the sequence shown

VALVE DIMENSIONS

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

FASTENER TIGHTENING SPECIFICATIONS

Left Timing Chain Cover, Tightening Specifications and Sequence

Tighten bolts in 4 stages as follows

Right Timing Chain Cover, Tightening Specifications and Sequence

Tighten bolts in 4 stages as follows

Lower Timing Chain Cover, Tightening Specifications and Sequence

Tighten the bolts in 3 steps according to the tightening sequence

Cylinder Head Cover, Tightening Specifications and Sequence

Tighten the cylinder head cover bolts -arrows- in a diagonal sequence in stages to 9 Nm.

Cylinder Head, Tightening Specifications and Sequence

Note. Replace bolts which have been tightened to an additional torque.

Tighten the bolts in 5 steps according to the tightening sequence

Left Cylinder Head Guide Frame, Tightening Specifications and Sequence

Tighten the bolts and nuts in 2 steps in the sequence shown

Right Cylinder Head Guide Frame, Tightening Specifications and Sequence

Tighten the bolts and nuts in 2 steps in the sequence shown

COMPRESSION, CHECKING

Special tools and workshop equipment required

1. Hinged Socket 3220
2. Compression Tester V.A.G 1763 with Adapter V.A.G 1763/8

Procedure

1. Engine oil temperature approximately 80 °C (176 °F)
2. Battery voltage at least 12.5 V.

Carefully pull the engine cover off the 4 bolts one after the other -arrows-.

Scheme 456

Disconnect the connector on the fuel pressure regulator valve -N276- -1- on the cylinder bank 1 (right) rail.

Scheme 457

In order to reduce the fuel pressure in the fuel rail, start the engine briefly.

Remove all the glow plugs. Refer to Removal and Installation .

Scheme 458

Install the V.A.G 1763/8 in place of the glow plugs and connect the V.A.G 1763.

Scheme 459

Note. Using the tester operating instructions.

Have a second technician operate the starter until the test stops showing an increase in pressure.

Repeat procedure on each cylinder.

Assembling

Assemble in reverse order of disassembling. Note the following

Install the glow plugs. Refer to Removal and Installation .

If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control module. "Check the DTC memory" .

CAMSHAFT, MEASURING AXIAL PLAY

Special tools and workshop equipment required

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

Procedure

Remove the guide frame. Refer to LEFT CYLINDER HEAD CAMSHAFT .

Secure the VAS 6079 on the cylinder head with the VW 387 as illustrated.

Determine the axial play on the intake camshaft -arrows-.

Scheme 460

1. Specified value: 0.03 to 0.08 mm
2. Wear limit 0.12 mm

Determine the axial play on the exhaust camshaft -arrows-.

Scheme 461

1. Specified value: 0.03 to 0.08 mm
2. Wear limit 0.12 mm

CAMSHAFT, MEASURING RADIAL PLAY

Special tools and workshop equipment required

1. Plastigage

Procedure

Removing cam follower. Refer to LEFT CYLINDER HEAD CAMSHAFT .

Clean the bearing and the bearing journals.

Place Plastigage over entire width of bearing journal or into bearing.

1. Plastigage must rest in center of bearing.

Re-install the camshafts, mount the bearing bracket and tighten to 10 Nm. (Scheme 454), do not turn the camshafts while doing this.

Remove the bearing bracket and camshafts.

Compare width of Plastigage with calibrated scale.

Radial clearance

1. New: 0.035 to 0.085 mm
2. Wear limit: 0.100 mm

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. Socket T40058
2. 0.20 mm 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 and RIGHT CYLINDER HEAD COVER .

Vehicles Built through 05.10

Loosen the hose clamp -arrow-, remove the air duct hose and move it to the side.

Scheme 462

All Vehicles

Insert the T40058 guide pins as follows

Scheme 463

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

Turn the crankshaft with the T40058 in direction of engine rotation -arrow- until the cam on the balance element which is to be checked faces upward.

Scheme 464

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

Scheme 465

If a 0.20 mm feeler gauge can slide between the cam lobes and roller rocker lever, replace the adjusting element. Refer to LEFT CYLINDER HEAD CAMSHAFT .

Final Procedures

Note. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model .

Install the air duct hose and screw-type clamps. (Scheme 467)

Scheme 466

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

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 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.

Secure the VAS 6079 on the cylinder head with the VW 387 as illustrated.

Scheme 467

Determine tip clearance.

1. Wear limit: 1.0 mm

If 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.

VALVES, CHECKING

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

If there are clear traces of wear, replace valve.

LEFT TIMING CHAIN COVER

Special tools and workshop equipment required

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

Removing

Remove the left intermediate pipe. Refer to LEFT INTERMEDIATE PIPE .

Remove the exhaust gas recirculation (EGR) cooler switch-over valve 2 -N381- -3-.

Remove the bolts -arrows-.

Scheme 468

Push the left rear coolant pipe to the side and remove the coolant hose -2-.

Note. Ignore -1-.

Remove the bolts -3- and -4- and remove the exhaust gas recirculation pipes.

Scheme 469

Note. Ignore -1 and 2-.

Remove the bolts -1 through 4- and remove the left timing chain cover.

Scheme 470

Installing

1. Tightening specifications, refer to «TURBOCHARGER OVERVIEW»(/audi/q7/4l-2009-2015/remont/blowers-superchargers-turbochargers/#30l-turbocharger-supercharger-engine-codes-cata__turbocharger-overview) and «EXHAUST GAS RECIRCULATION OVERVIEW»(/audi/q7/4l-2009-2015/remont/exhaust/#30l-exhaust-system-emission-controls-engine-codes-cata__exhaust-gas-recirculation-overview) .

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

Remove old sealant from the grooves in the timing chain cover as well as from the sealing surfaces.

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

Scheme 471

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 1.5 mm).

Scheme 472

Apply a sealant bead to the clean sealing surface of the left timing chain cover as shown in the illustration.

Scheme 473

1. The groove -1- of sealing surface must be completely filled with sealant.
2. The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

Install the seal -2-.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Apply a 3 mm diameter sealant bead to the transitions between the cylinder head and lower timing chain cover -arrows- as illustrated.

Scheme 474

Note. The timing chain cover must be installed within 5 minutes after applying the sealant

Position the left timing chain cover and tighten the bolts. (Scheme 445)

The rest of the installation is performed in reverse order of removal, noting the following

Install the left rear coolant pipes. Refer to LEFT REAR COOLANT PIPE .

Install the left intermediate pipe. Refer to LEFT INTERMEDIATE PIPE .

RIGHT TIMING CHAIN COVER

Special tools and workshop equipment required

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

Removing

Remove vacuum pump. Refer to Removal and Installation .

Scheme 475

Free up electrical wiring harness -arrows-.

Scheme 476

Remove the bolt -1- and the bracket -2-.

Remove the bolts -1 through 4- and remove the right timing chain cover.

Scheme 477

Installing

1. Tightening specifications, refer to «CYLINDER HEAD COVER OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-cover-overview)

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

Remove old sealant form the grooves in the timing chain cover as well as from the sealing surfaces.

Remove the remaining sealant on the left timing chain and cylinder head covers, for example with a rotating plastic brush.

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 1.5 mm).

Apply a sealant bead to the clean sealing surface of the right timing chain cover as shown in the illustration.

1. The groove -1- of sealing surface must be completely filled with sealant.
2. The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

Install the seal -2-.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Apply a 3 mm diameter sealant bead to the transitions between the cylinder head and lower timing chain cover -arrows- as illustrated.

Scheme 478

Note. The timing chain cover must be installed within 5 minutes after applying the sealant

Position the right timing chain cover and tighten the bolts. (Scheme 446)

The rest of the installation is performed in reverse order of removal, noting the following

Install the vacuum pump. Refer to Removal and Installation .

LOWER TIMING CHAIN COVER

Special tools and workshop equipment required

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

Removing

1. Transmission removed.
2. Engine oil drained. Refer to Maintenance Procedures .

Remove the drive plate. Refer to DRIVE PLATE .

Remove the intermediate pipe and intermediate flange. Refer to LEFT INTERMEDIATE PIPE , and RIGHT INTERMEDIATE PIPE and INTERMEDIATE FLANGE .

Remove the timing chain covers. Refer to LEFT TIMING CHAIN COVER and RIGHT TIMING CHAIN COVER .

If equipped, remove the nuts -arrows- and the connector bracket from the left engine support.

Scheme 479

Remove the bolts -arrows- and remove the oil return pipe -1- from the cylinder block.

Scheme 480

Note. Lay a cloth below to catch the draining engine oil.

Remove the bolts -1 through 9- 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. Tightening specifications, refer to «SUBFRAME ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-engine-assembly-engine-codes-cata) and «TURBOCHARGER OVERVIEW»(/audi/q7/4l-2009-2015/remont/blowers-superchargers-turbochargers/#30l-turbocharger-supercharger-engine-codes-cata__turbocharger-overview) .

Remove old sealant form the grooves in the timing chain cover as well as from the sealing surfaces.

Remove any sealant residue on the lower timing chain cover and cylinder block with a rotating plastic brush.

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 1.5 mm).

Install the seals -2- and -5-.

Scheme 481

Apply a bead of sealant -1- and -4- on the clean sealing surfaces on the lower timing chain cover as illustrated.

1. Completely fill the grooves on the sealing surfaces with sealant.
2. The sealant bead must be 1.5 to 2.0 mm above the sealing surface.
3. The bead of sealant around the holes -3- and -6- must be 1.5 to 2.0 mm thick.

Note. The timing chains cover must be installed within 5 minutes after applying the sealant

Make sure the dowel sleeves are inside the cylinder block; if not, install them.

Install the lower timing chain cover and tighten the bolts. (Scheme 447)

The rest of the installation is performed in reverse order of removal, noting the following

Install the lower section of the oil return line. Refer to TURBOCHARGER OVERVIEW .

Install the timing chain covers. Refer to LEFT TIMING CHAIN COVER and RIGHT TIMING CHAIN COVER .

Install the intermediate pipe and intermediate flange. Refer to LEFT INTERMEDIATE PIPE , and RIGHT INTERMEDIATE PIPE and INTERMEDIATE FLANGE .

Installing drive plat. Refer to DRIVE PLATE .

Fill engine oil and check oil level. Refer to Maintenance Procedures .

CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS

Special tools and workshop equipment required

1. Crankshaft Holder 3242
2. Socket T40058
3. Adjusting Pin T40060 (quantity: 2)
4. Adapter T40061
5. Adapter T40062
6. Two 3.3 mm drill bits

Removing

1. Engine and transmission installed.

Note. If working on just one of the cylinder heads, it is not necessary to remove the timing chain cover on the opposite cylinder head.

Remove the timing chain cover. Refer to LEFT TIMING CHAIN COVER and RIGHT TIMING CHAIN COVER .

Insert the T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

Use the T40058 to rotate the crankshaft to "TDC".

Note. The T40060 has a flat part -2- which makes it easier to insert if the camshaft and the cylinder head are slightly offset. Insert the pin so that the bolt -1- is perpendicular to the camshaft axle. Move the bolt -1- 90° -arrow- so that it is perpendicular to the camshaft axle and it is possible to attain the correct "TDC" position.

Check whether camshafts of both cylinder heads stand in "TDC" position.

Scheme 482

1. It must be possible to secure the camshafts with the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 1 (right).

Scheme 483

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 2 (left).

Note. To collect escaping engine oil, place a clean cloth under the upper section of the oil pan.

Remove the bolt -arrow- for the "TDC" marking from the upper section of the oil pan by using a long hex socket wrench with a ball head.

Scheme 484

Install the 3242 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and slightly to completely center the bolt, if necessary.

Scheme 485

To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Scheme 486

Push the tensioning track of the chain tensioner for the left camshaft timing chain in direction of -arrow- and secure the chain tensioner with a 3.3 mm drill bit -1-.

Remove the bolt -3- and remove the tensioning rail.

Scheme 487

Remove the bolts -1- for the guide rail and bolts -2- for the camshaft chain sprocket.

Remove the camshaft chain sprocket and guide rail.

To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Push the chain tensioner guide rail for the right camshaft timing chain in direction of -arrow- and secure the chain tensioner with a 3.3 mm drill bit -1-.

Scheme 488

Remove the chain tensioner bolts -1- and camshaft chain sprocket bolts -3- and -2-.

Scheme 489

Remove the camshaft chain sprocket and chain tensioner.

INSTALLING

1. For the correct tightening specifications, refer to «CAMSHAFT TIMING CHAINS OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-timing-chains-overview) .
2. Secure crankshaft -1- in "TDC" position using 3242.

Note. Replace bolts which have been tightened to an additional torque.

Check whether camshafts of both cylinder heads stand in "TDC" position.

Scheme 490

1. It must be possible to secure the camshafts with the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 1 (right).

Scheme 491

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 2 (left).

Remove the T40060 from both camshafts.

Note. If the camshafts are not secured, it is possible to correct them slightly with the T40061 by installing the camshaft chain sprocket on the camshaft.

Install the left camshaft timing chain with the camshaft chain sprocket, the guide rail and the tensioning rail.

1. The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in the camshaft.

Tighten the bolts -1- and -3- for the guide rail and the tensioning rail.

Scheme 492

Install both camshaft chain sprocket bolts -2- loosely.

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

Secure the left camshaft with the T40060.

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Pull the drill bit -4- out of the alignment hole, thereby releasing the chain tensioner.

Install the right camshaft timing chain with the chain sprocket and chain tensioner.

Scheme 493

1. The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in the camshaft.

Tighten the chain tensioner bolts -1-.

Install both camshaft chain sprocket bolts -2- loosely.

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

Secure the right camshaft with the T40060.

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Pull the drill bit -3- out of the alignment hole, thereby releasing the right chain tensioner.

Tighten the right camshaft chain sprocket using the T40062 and torque wrench to 20 Nm in direction of -arrow- and hold.

Scheme 494

Fasten bolts -1- and -2-.

Remove the T40062 and T40060.

Tighten the remaining bolts for the right camshaft chain sprocket.

Tighten the left camshaft chain sprocket using the T40062 and torque wrench to 15 Nm in direction of -arrow- and hold.

Scheme 495

Fasten bolts -1- and -2-.

Remove the T40062 and T40060.

Tighten the remaining bolts for the left camshaft chain sprocket.

Remove the 3242.

CHECKING THE VALVE TIMING

Turn the crankshaft two turns until the crankshaft is just in front of "TDC".

Lock the crankshaft -1- from turning using the 3242 to 20 Nm.

Check whether camshafts of both cylinder heads stand in "TDC" position.

1. It must be possible to secure the camshafts with the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 1 (right).

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 2 (left).

CORRECTING THE VALVE TIMING

If one of the camshafts does not lock, loosen all the bolts -arrows- for that particular camshaft chain sprocket about 1 turn.

Scheme 496

Mount the T40061 over the bolt heads.

Scheme 497

Turn the camshaft by the T40061 just a little back and forth until it is possible to insert the T40060.

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Tighten the bolts for the camshaft chain sprocket with the T40061 and the T40060 still attached to approximately 5 Nm.

Remove the T40060 and T40061.

Tighten the camshaft chain sprocket bolts to final torque.

Repeat the procedure on the other cylinder bank if necessary.

Remove the 3242.

Check the valve timing once again CHECKING THE VALVE TIMING .

The rest of the installation is performed in reverse order of removal, noting the following

Tighten the bolt for the "TDC" marking in the upper section of the oil pan UPPER OIL PAN OVERVIEW .

Install the timing chain cover. Refer to LEFT TIMING CHAIN COVER and RIGHT TIMING CHAIN COVER .

CAMSHAFT TIMING CHAINS

Special tools and workshop equipment required

1. Crankshaft Holder 3242
2. Key T40049
3. Adjusting Pin T40060 (quantity: 2)
4. Adapter T40061
5. Adapter T40062
6. Two 3.3 mm drill bits

Removing

1. Transmission removed.

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

Attach the T40049 to the back of the crankshaft using two old drive plate bolts -arrows-.

Scheme 498

Note. The T40060 has a flat part -2- which makes it easier to insert if the camshaft and the cylinder head are slightly offset. Insert the pin so that the bolt -1- is perpendicular to the camshaft axle. Move the bolt -1- 90° -arrow- so that it is perpendicular to the camshaft axle and it is possible to attain the correct "TDC" position.

Use the T40049 to rotate the crankshaft to "TDC"

Check whether camshafts of both cylinder heads stand in "TDC" position.

1. It must be possible to secure the camshafts with the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 1 (right).

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 2 (left).

Remove the bolt -arrow- for the "TDC" marking from the upper section of the oil pan by using a long hex socket wrench with a ball head.

Install the 3242 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and slightly to completely center the bolt, if necessary.

To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Push the tensioning track of chain tensioner for the left camshaft timing chain in direction of -arrow- and secure the chain tensioner with a 3.3 mm drill bit -1-.

Remove the T40060 from both camshafts.

Remove the bolt -3- and remove the tensioning rail.

Remove the bolts -1- for the guide rail and bolts -2- for the camshaft chain sprocket.

Remove the camshaft chain sprocket, guide rail and left camshaft timing chain.

To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Push the chain tensioner guide rail for the right camshaft timing chain in direction of -arrow- and secure the chain tensioner with a 3.3 mm drill bit -1-.

Remove the chain tensioner bolts -1- and camshaft chain sprocket -3- and bolts -2-.

Remove the camshaft chain sprocket, chain tensioning and right camshaft timing chain.

Installing

1. For the correct tightening specifications, refer to «CAMSHAFT TIMING CHAINS OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__camshaft-timing-chains-overview) .
2. Secure crankshaft -1- in "TDC" position using 3242.
3. Drive chain for timing mechanism installed. Refer to «TIMING MECHANISM DRIVE CHAIN»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__timing-mechanism-drive-chain) .

Note. Replace bolts which have been tightened to an additional torque.

Check whether camshafts of both cylinder heads stand in "TDC" position.

1. It must be possible to secure the camshafts with the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 1 (right).

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 2 (left).

Remove the T40060 from both camshafts.

Note. If the camshafts are not secured, it is possible to correct them slightly with the T40061 by installing the camshaft chain sprocket on the camshaft.

Install the left camshaft timing chain with the camshaft chain sprocket, the guide rail and the tensioning rail.

1. The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in the camshaft.

Tighten the bolts -1- and -3- for the guide rail and the tensioning rail.

Install both camshaft chain sprocket bolts -2- loosely.

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

Secure the left camshaft with the T40060.

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Pull the drill -4- out of the alignment hole, thereby releasing the chain tensioner.

Install the right camshaft timing chain with the chain sprocket and chain tensioner.

1. The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in the camshaft.

Tighten the chain tensioner bolts -1-.

Install both camshaft chain sprocket bolts -2- loosely.

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

Secure the right camshaft with the T40060.

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Pull the drill bit -3- out of the alignment hole, thereby releasing the right chain tensioner.

Pre-tighten the right camshaft chain sprocket using the T40062 and torque wrench to 20 Nm in direction of -arrow- and hold.

Fasten bolts -1- and -2-.

Remove the adapter T40062 and T40060.

Tighten the remaining bolts for the right camshaft chain sprocket.

Pre-tighten the left camshaft chain sprocket using the T40062 and torque wrench to 15 Nm in direction of -arrow- and hold.

Fasten bolts -1- and -2-.

Remove the T40062 and T40060.

Tighten the remaining bolts for the left camshaft chain sprocket.

Remove the 3242.

Turn the crankshaft 2 turns using the T40049 until it is just in front of "TDC".

Lock the crankshaft -1- from turning using the 3242 to 20 Nm.

Check whether camshafts of both cylinder heads stand in "TDC" position.

1. It must be possible to secure the camshafts with the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 1 (right).

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft on cylinder bank 2 (left).

If one of the camshafts does not lock, loosen all the bolts -arrows- for that particular camshaft chain sprocket about 1 turn.

Mount the T40061 over the bolt heads.

Turn the camshaft by the T40061 just a little back and forth until it is possible to insert the T40060.

1. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Tighten the bolts for the camshaft chain sprocket with the T40061 and the T40060 still attached to approximately 5 Nm.

Remove the T40060 and T40061.

Tighten the camshaft chain sprocket bolts to final torque.

Repeat the procedure on the other cylinder bank if necessary.

Remove the 3242.

Check the valve timing once again CHECKING THE VALVE TIMING .

The rest of the installation is performed in reverse order of removal, noting the following

Tighten the bolt for the "TDC" marking in the upper section of the oil pan. Refer to UPPER OIL PAN OVERVIEW .

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

Fill engine oil and check oil level. Refer to Maintenance Procedures .

TIMING MECHANISM DRIVE CHAIN

Special tools and workshop equipment required

1. Locking Pin T40071
2. 3.3 mm diameter drill bit

Removing

1. Transmission removed.

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAINS .

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

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

Scheme 499

Remove the bolts -1- and the guide rail.

Remove the bolts -2- and -3- and remove the chain sprockets and drive chain.

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «TIMING MECHANISM DRIVE CHAIN OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata) .

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

Install the camshaft timing chains, refer to CAMSHAFT TIMING CHAINS .

Fill engine oil and check oil level. Refer to Maintenance Procedures .

POWER TAKE-OFF DRIVE CHAIN

Special tools and workshop equipment required

1. Crankshaft Holder 3242
2. Diesel Injection Pump Locking Pin 3359
3. Key T40049
4. 3.3 mm diameter drill bit

Removing

1. Transmission removed.

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

Attach the T40049 to the back of the crankshaft using two old drive plate bolts -arrows-.

Remove the bolt -arrow- for the "TDC" marking from the upper section of the oil pan by using a long hex socket wrench with a ball head.

Install the 3242 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and slightly to completely center the bolt, if necessary.

Lock the rear balance shaft on the engine using the 3359 and loosen the bolts -arrows- for balance shaft chain sprocket.

Scheme 500

To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Scheme 501

Push the slide rail for the chain tensioner in direction of -arrow- and then lock the chain tensioner using a 3.3 mm drill bit -4-.

Remove the bolts -1- and -2- and remove the chain tensioner, chain sprocket -3- for the balance shaft and the chain.

Installing

1. For the correct tightening specifications, refer to «POWER TAKE-OFF DRIVE CHAIN OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata) .
2. Secure crankshaft -1- in "TDC" position using 3242.

Lock the rear balance shaft -arrow- to the engine with the 3359.

Scheme 502

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

1. The slots in the chain sprocket -3- must be in the center position to the threaded holes in the balance shaft.

Tighten the chain tensioner bolts -1- and -2-.

Note. Ignore -4- and -arrow-.

Install the chain sprocket bolts -arrows- loosely.

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

Remove the drill from the alignment hole.

Scheme 503

Push a screwdriver in direction of -arrow- against the chain tensioner guide rail while tightening the chain sprocket bolts -1-.

Remove the 3359.

The rest of the installation is performed in reverse order of removal, noting the following

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

Fill engine oil and check oil level. Refer to Maintenance Procedures .

BALANCE SHAFT

Special tools and workshop equipment required

1. Diesel Injection Pump Locking Pin 3359

Removing

1. Transmission removed.

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

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

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

Lock the front balance shaft to the engine with the 3359.

Scheme 504

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

Remove the bolts -arrows- at the back of the motor and remove the chain sprocket from the balance weight.

Remove the bolt -arrow- at the back of the engine and remove the balance weight from the balance shaft.

Remove the bolts -arrows- and remove the balance shaft bearing end bracket.

Scheme 505

Remove the balance shaft from the cylinder block.

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «BALANCE SHAFT OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata) .
2. Secure crankshaft -1- in "TDC" position using 3242.

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, BELT PULLEY SIDE .

Fill engine oil and check oil level. Refer to Maintenance Procedures .

LEFT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80-200

Removing

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove the upper section of the intake manifold. Refer to Removal and Installation .

Scheme 506

Remove the oil filler tube by lifting the strap -1- and turning the tuber counter-clockwise -arrow-.

Scheme 507

Remove electrical connectors from bracket and disconnect.

Scheme 508

1. For catalyst temperature sensor 1 -G20- (orange) - only engines meeting emissions standard BIN 5
2. For exhaust gas temperature 3 -G495- (brown)

Disconnect the glow plug connector for cylinders "4" and "5".

Disconnect the electrical connectors -1 through 4-.

Scheme 509

Free up the wiring harness using the 80 - 200.

Vehicles Built through 05.10

Free up the wiring on the cylinder head.

Remove the bolts -arrows- and move the brackets -1- and -2- and wiring harness with the wiring harness to the side.

Scheme 510

Vehicles built from 06.10

Free up the electric wires on the cylinder head.

Remove the bolts -arrows- and move the brackets -1- and -2- and wiring harness to the side.

Scheme 511

All vehicles

Mark the injector high pressure line for re-installing.

Remove the high pressure lines by loosening the union nuts -1 through 6-. Refer to Description and Operation .

Scheme 512

Remove the injectors. Refer to Description and Operation .

Scheme 513

Loosen the cylinder head cover bolts -arrows- in a diagonal sequence.

Remove the bolts and the cylinder head cover.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «CYLINDER HEAD COVER OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-cover-overview) .

Note. Replace 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 cylinder head cover bolts. (Scheme 438)

Install the injectors, high pressure lines and upper section of the intake manifold. Refer to Removal and Installation .

Fuel system, performing leak test. Refer to FUEL SYSTEM, CHECKING FOR LEAKS .

RIGHT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80-200

Removing

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove air filter insert. Refer to Removal and Installation .

Remove the electrical connector -arrow- from the bracket and disconnect it.

Scheme 514

Remove the connector bracket bolt on the cylinder head cover.

Disconnect cylinder "1" glow plug connector.

Disconnect the connectors -1 through 7- and free up the wiring harness using the 80 - 200.

Scheme 515

Note. 4- not on vehicles built from 06.10.

Free up the wiring harness on the cylinder head cover using the 80 - 200.

Remove the bolt -1- and move the bracket -2- and wiring harness to the side.

Note. Ignore -arrows-.

Mark the injector high pressure line for re-installing.

Remove the high pressure lines by loosening the union nuts -1 through 6-. Refer to Description and Operation .

Scheme 516

Remove the pressure retention valve -arrow- from the bracket with the fuel hoses still connected and move it to the side.

Scheme 517

Remove the pressure retention valve bracket.

Remove the injectors. Refer to Removal and Installation .

Loosen the cylinder head cover bolts -arrows- in a diagonal sequence.

Remove the bolts and the cylinder head cover.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «CYLINDER HEAD COVER OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-cover-overview) .

Note. Replace the cylinder head seal if it is damaged. Replace the cylinder head cover bolts when replacing the damaged seal. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model .

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

Tighten cylinder head cover bolts. (Scheme 438)

Install the injectors, high pressure lines and fuel filter. Refer to Removal and Installation .

Fuel system, performing leak test. Refer to FUEL SYSTEM, CHECKING FOR LEAKS .

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Retainer 3036
3. Hose Clamps Up to 25 mm Dia. 3094
4. Engine Bung Set VAS 6122
5. Puller T10320
6. Crankshaft Holder 3242
7. Adjusting Pin T40060
8. Sealant

Removing

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

Remove the affected camshaft timing chain from the camshaft. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove the upper section of the intake manifold. Refer to Removal and Installation .

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

Left Cylinder Head

Remove the upper left coolant pipe. Refer to LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10 .

Remove the high pressure pump toothed belt and the belt tensioning roller. Refer to Removal and Installation .

Scheme 518

Loosen the toothed belt drive sprocket bolt -1- 2 turns using the 3036.

Scheme 519

Remove the toothed belt drive sprocket using the T10320.

Scheme 520

Remove the bolts -arrows- and leave the rear toothed belt guard in its installation position.

Scheme 521

Remove the bolt -2- for the oil dipstick guide tube.

Scheme 522

Note. Ignore -1-.

Mark the injector high pressure line for re-installing.

Remove the union nuts -2- and -3-, free up and remove the high pressure line.

Scheme 523

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

Remove the T-connector from the coolant hose -arrow-.

Scheme 524

Disconnect the connector -1- on the intake flap motor 2 -V275- -4-.

Scheme 525

Note. Ignore -2 and 3- and -arrows-.

Vehicles Built from 06.10

Note. Place a cloth underneath to soak up any escaping power steering fluid.

Clamp off the power steering pump hydraulic hose -1- with a 3094.

Remove the bolts -2- and move the hydraulic line to the rear.

Scheme 526

Seal the open lines and connections with clean plugs from the engine bung set VAS 6122.

All Vehicles

Loosen the clamp -arrow- and remove the exhaust gas recirculation pipe -1-.

Scheme 527

Right Cylinder Head

Remove the right intermediate pipe. Refer to RIGHT INTERMEDIATE PIPE .

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

Remove the bolts -arrows- and the high pressure line protective plate.

Mark the injector high pressure line for re-installing.

Remove the union nuts -1- and -4-, free up and remove the high pressure line.

Note. Ignore -2 and 3-.

Remove the engine lifting eyelet bolts -1- and -2-.

Scheme 528

Free up the wiring harness using 80 - 200 -arrow-.

Loosen the clamp -arrow- and remove the coolant pipe.

Scheme 529

Disconnect the glow plug connectors for cylinders "2" and "3".

Disconnect the connector -1- on the intake flap motor -V157-.

Scheme 530

Note. Ignore -arrows-.

Remove the connector -2- (orange) for exhuast gas recirculation (EGR) temperature sensor -G98- from the bracket and disconnect it.

Scheme 531

Note. Ignore -1-.

Note. Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the bolts -arrows- and then move the fuel rail to the side with the hoses still attached.

Scheme 532

Note. Ignore -1 and 2-.

Continued for Both Sides

Scheme 533

Remove the bolts and the cylinder head carefully.

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-overview) .

Note. Replace bolts which have been tightened to an additional torque. Replace self-locking nuts, sealing rings, seals and O-rings. It is not permitted to re-work the cylinder heads on TDI engines When installing a replacement cylinder head with the camshaft installed, coat the contact surfaces between the hydraulic adjusting elements, the roller rocker levers and cam running surfaces with oil. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model . The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

Before positioning the cylinder head, adjust the crankshaft and camshafts to "TDC"

1. The 3242 must be installed in the "TDC" position for the crankshaft -1-.

1. The camshafts on both cylinder head must be locked by the T40060.
2. The bolt -arrow- in the T40060 must be perpendicular to the center axle of the camshaft.

Note the cylinder head gasket identification

1. Holes
2. Part number

Note. If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket. If the crankshaft drive is replaced, measure the piston projection in TDC to determine the new cylinder head. Refer to PISTON PROJECTION, MEASURING AT TDC . The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

Clean any oil or grease off the sealing surfaces.

Note. Note the expiration date of the sealing compound. Cut the tube nozzle at the front marking (nozzle diameter approximately 5 mm). Components that have had sealant applied to them must be bolted within 15 minutes.

Left Cylinder Head

Apply a bead of sealant -1- and -2- on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.

Scheme 534

Apply the sealant in the amounts specified.

Scheme 535

1. a = 7 mm
2. b = 7 mm
3. c = 7 mm

Set cylinder head gasket in place.

Apply sealant beads -1- and -2- to the clean sealing surfaces as illustrated.

Scheme 536

Right Cylinder Head

Apply a bead of sealant -1- and -2- on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.

Scheme 537

Apply the sealant in the amounts specified.

1. a = 7 mm
2. b = 7 mm
3. c = 7 mm

Set cylinder head gasket in place.

Apply sealant beads -1- and -2- to the clean sealing surfaces as illustrated.

Scheme 538

Continued for Both Sides

Scheme 539

1. Pay close attention to alignment bushings in cylinder block -arrows-.
2. Pay attention to installation position of the cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.

Set cylinder head in place.

Insert new cylinder head bolts and tighten by hand.

Tighten the cylinder head bolts. (Scheme 442)

Note. There is no requirement to tighten the cylinder head bolts after repairs.

Left Cylinder Head

Install the exhaust gas recirculation pipe. Refer to EXHAUST GAS RECIRCULATION OVERVIEW .

Install oil dipstick guide tube. Refer to UPPER OIL PAN OVERVIEW .

Installing the upper left coolant pipe. Refer to LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10 .

Install the rear toothed belt guard, the toothed belt tensioning roller and the high pressure pump toothed belt. Refer to Removal and Installation .

Install the hydraulic pipe. Refer to Description and Operation .

Right Cylinder Head

Install the fuel rail. Refer to Removal and Installation .

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

Install the right intermediate pipe. Refer to RIGHT INTERMEDIATE PIPE .

Continued for Both Sides

High pressure lines, installing. Refer to Removal and Installation .

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

Install the upper section of the intake manifold. Refer to Removal and Installation .

Install the camshaft timing chains CHECKING THE VALVE TIMING .

Change engine oil. Refer to Maintenance Procedures .

Replace coolant, refer to "Filling" under COOLING SYSTEM, DRAINING AND FILLING .

Fuel system, performing leak test. Refer to FUEL SYSTEM, CHECKING FOR LEAKS .

CAMSHAFT SEAL

Special tools and workshop equipment required

1. Seal Puller - General Usage 2085
2. Retainer 3036
3. M10 x 1.25 x 40 hex bolt from Seal Installer 3241
4. Assembly Tool T10053
5. Puller T10320

Procedure

1. Tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-overview) .

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove the upper section of the intake manifold. Refer to Removal and Installation .

Remove the high pressure pump toothed belt. Refer to Removal and Installation .

Loosen the toothed belt drive sprocket bolt -1- 2 turns using the 3036.

Scheme 540

Remove the toothed belt drive sprocket using the T10320.

Scheme 541

Turn the inner part of the 2085 3 turns from the outer part and lock the inner part with the knurled bolt.

Scheme 542

Lubricate the seal remover threaded head, position it, and then install it into the shaft seal as far as possible using strong force.

Loosen the knurled bolt and rotate the inner section against the camshaft until the shaft seal is removed.

Secure the seal remover in a vise at the flat spots and remove the seal using pliers.

Clean running and sealing surface.

Install the new seal all the way using the pressure sleeve from the T10053 using the hex head bolt M10 x 1.25 x 40 -arrow- from the 3241.

Scheme 543

Assembly is performed in reverse order of removal, noting the following

Install the high pressure pump toothed belt and the upper section of the intake manifold. Refer to Removal and Installation .

LEFT CYLINDER HEAD CAMSHAFT

Special tools and workshop equipment required

1. Puller T10320
2. Camshaft Fitting Tool T40094
3. Camshaft Fitting Tool T40095
4. Component of T40096 T40096
5. Pry Lever - Rmv Outside Mirror 80-200
6. Retainer 3036
7. Hand drill with plastic brush attachment
8. Protective eyewear
9. Sealant

Removing

Remove the affected camshaft timing chain from the camshaft. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove the upper section of the intake manifold. Refer to Removal and Installation .

Remove the high pressure pump toothed belt. Refer to Removal and Installation .

Loosen the toothed belt drive sprocket bolt -1- 2 turns using the 3036.

Remove the toothed belt drive sprocket using the T10320.

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

Remove the exhaust gas recirculation (EGR) cooler switch-over valve -N345- -1- from the bracket.

Scheme 544

Remove the bolt -4- and the engine cover bolts -2-.

Free up the wiring harness -3- on the top of the coolant pipe on the left side.

Note. Ignore -arrows-.

Note. Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the high pressure line union nut -1-.

Remove the bolts -arrows- and remove the fuel rail from the left cylinder head.

Loosen the guide frame bolts and nuts in the sequence -18 to 1-.

Note. Be careful of the roller rocker lever and the adjusters when removing the camshafts.

Carefully remove the bearing bracket and camshafts.

Installing

1. Tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-overview) , «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

Note. Replace the front cover in the cylinder head on the right side.

Remove the sealant residue on the cylinder head and guide frame and the upper section of the oil pan, for example using a rotating plastic brush.

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

Lubricate the running surfaces of both camshafts.

Set up the T40094 as follows

Scheme 545

Install the T40094/2 in -A-.

Install the T40094/1 in -D-.

Install the exhaust camshaft -1- into the T40094/1 and T40094/2.

Scheme 546

Turn the exhaust camshaft so that it can be locked with the straight-edge in the "TDC" position -arrow-.

Mount the T40096 onto the teeth of the exhaust camshaft so that one arm of the clamping device engages in one sprocket half.

Tension the clamping devise with the thumb wheel until the tooth faces align.

Place the intake camshaft -2- into the T40094.

Scheme 547

1. The securing pin -3- must engage in the groove on the intake camshaft.

Push the exhaust camshaft -1- toward the intake camshaft -arrows- until the splines engage.

Make sure the camshaft is positioned correctly

Scheme 548

1. The notches -arrows- on both camshafts must face upward.

Place the bearing brackets -1- on both camshafts.

Scheme 549

1. All the camshaft bearings must lie on the camshafts.

Mount the T40095 onto the camshafts by aligning the pliers and tension with the knurled nuts -2-.

Tension the camshafts by tightening the nuts -3-.

Make sure the alignment pins -arrows- are in the cylinder head. Insert any missing alignment pins.

Scheme 550

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Note. The guide frame is shown without the camshafts.

Turn the guide frame around.

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

Scheme 551

1. The grooves 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.

Note. The guide frame must be installed within 5 minutes after applying the sealant.

Mount the guide frame together with both camshaft and the T40095 to the cylinder head.

Tighten the guide frame bolts. (Scheme 454)

Remove the T40095 and T40096.

Note. After installing the guide frame, let the sealant harden for approximately 30 minutes.

The rest of the installation is performed in reverse order of removal, noting the following

Install the fuel rail and the high pressure lines. Refer to Removal and Installation .

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

Camshaft seal, removing and installing. Refer to CAMSHAFT SEAL .

Install the high pressure pump toothed belt and the upper section of the intake manifold. Refer to Removal and Installation .

Install the camshaft timing chains CHECKING THE VALVE TIMING .

RIGHT CYLINDER HEAD CAMSHAFT

Special tools and workshop equipment required

1. Puller T10320
2. Camshaft Fitting Tool T40094
3. Camshaft Fitting Tool T40095
4. Component of T40096 T40096
5. Pry Lever - Rmv Outside Mirror 80-200
6. Retainer 3036
7. Hand drill with plastic brush attachment
8. Protective eyewear
9. Sealant

Removing

Remove the affected camshaft timing chain from the camshaft. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

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

Note. Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the union nuts -1- and -2-.

Remove the bolts -arrows- and then move the fuel rail to the side with the hoses still attached.

Free up the wiring harness -arrow- using the 80 - 200.

Note. Ignore -1 and 2-.

Loosen the guide frame bolts and nuts in the sequence -17 to 1-.

Note. Be careful of the roller rocker lever and the adjusters when removing the camshafts.

Carefully remove the bearing bracket and camshafts.

Installing

1. Tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-overview) , «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

Note. Replace the front cover in the cylinder head on the right side.

Remove the sealant residue on the cylinder head and guide frame and the upper section of the oil pan, for example using a rotating plastic brush.

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

Lubricate the running surfaces of both camshafts.

Set up the T40094 as follows

Install the T40094/2 in -B-.

Install the T40094/1 in -C-.

Install the exhaust camshaft -1- into the T40094/1 and T40094/2.

Turn the exhaust camshaft so that it can be locked with the straight-edge in the "TDC" position -arrow-.

Place the intake camshaft -2- into the T40094.

Scheme 552

1. The securing pin -3- must engage in the groove on the intake camshaft.

Mount the T40096 onto the teeth of the intake camshaft so that one arm of the clamping device engages in one sprocket half.

Tension the clamping devise with the thumb wheel until the tooth faces align.

Push the exhaust camshaft -1- toward the intake camshaft -arrows- until the splines engage.

Make sure the camshaft is positioned correctly

Scheme 553

1. The notches -arrows- on both camshafts must face upward.

Place the bearing brackets -1- on both camshafts.

Scheme 554

1. All the camshaft bearings must lie on the camshafts.

Mount the T40095 onto the camshafts by aligning the pliers and tension with the knurled nuts -2-.

Tension the camshafts by tightening the nuts -3-.

Make sure the alignment pins -arrows- are in the cylinder head. Insert any missing alignment pins.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Note. The guide frame is shown without the camshafts.

Turn the guide frame around.

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

Scheme 555

1. The grooves 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.

Note. The guide frame must be installed within 5 minutes after applying the sealant.

Mount the guide frame together with both camshaft and the T40095 to the cylinder head.

Tighten the guide frame bolts. (Scheme 455)

Remove the T40095 and T40096.

Note. After installing the guide frame, let the sealant harden for approximately 30 minutes.

The rest of the installation is performed in reverse order of removal, noting the following

Install the fuel rail and the high pressure lines. Refer to Removal and Installation .

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

Install the new cover with a suitable drift so that it is flush.

Install the camshaft timing chains CHECKING THE VALVE TIMING .

VALVE STEM SEALS, CYLINDER HEAD INSTALLED

Special tools and workshop equipment required

1. Hinged Socket 3220
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Knurled Spacer Ring VAS 5161/23-1 and Guide Plate VAS 5161/23

Removing

Remove all the glow plugs. Refer to Removal and Installation .

Camshafts, removing. Refer to LEFT CYLINDER HEAD CAMSHAFT , RIGHT CYLINDER HEAD CAMSHAFT .

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.

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

Mount the VAS 5161/23 on cylinder head.

Scheme 556

Secure the guide plate with the knurled screws VAS 5161/12.

Insert the drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

Install the sealing bolt VAS 5161/10 into the guide plate.

Scheme 557

Install the adapter VAS 5161/11 by hand into the glow plug thread.

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Scheme 558

Slide the knurled spacer ring VAS 5161/23-1 onto the installation cartridge VAS 5161/8.

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

1. Minimum pressure: 6 bar positive pressure.

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

At the same time, rotate installation cartridge knurled screw right until the 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 the installation cartridge with the knurled spacer ring.

Remove the valve spring and the valve spring plate.

Remove the valve stem seal with the 3364.

Scheme 559

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

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

Scheme 560

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

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

Scheme 561

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

Scheme 562

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with the 3365.

Remove plastic sleeve.

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

Scheme 563

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

Insert valve spring and valve spring plate.

Press the installation cartridge onto the insertion device for the valve retainers from above and take up the valve retainers.

Insert installation cartridge in the VAS 5161/23.

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.

Assembling

Assemble in reverse order of disassembling. Note the following

Camshafts, installing. Refer to LEFT CYLINDER HEAD CAMSHAFT and RIGHT CYLINDER HEAD CAMSHAFT .

Install the glow plugs. Refer to Removal and Installation .

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 Knurled Spacer Ring VAS 5161/23-1 and Guide Plate VAS 5161/23
4. Engine and Transmission Holder VAS 6095
5. Cylinder Head Tensioning Device VAS 6419

Removing

Camshafts, removing, refer to LEFT CYLINDER HEAD CAMSHAFT and RIGHT CYLINDER HEAD CAMSHAFT .

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.

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 seal that will be removed.

Scheme 564

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

Mount the VAS 5161/23 on cylinder head.

Secure the guide plate with the knurled screws VAS 5161/12.

Insert the drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Scheme 565

Slide the knurled spacer ring VAS 5161/23-1 onto the installation cartridge VAS 5161/8.

Engage pressure fork 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 the installation cartridge with the knurled spacer ring.

Remove the valve spring and the valve spring plate.

Remove the valve stem seal with the 3364.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with the 3365.

Remove plastic sleeve.

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

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

Insert valve spring and valve spring plate.

Press the installation cartridge onto the insertion device for the valve retainers from above and take up valve retainers.

Insert installation cartridge in VAS 5161/23.

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.

Assembling

Assemble in reverse order of disassembling. Note the following

Install the camshafts. Refer to LEFT CYLINDER HEAD CAMSHAFT and RIGHT CYLINDER HEAD CAMSHAFT .

Scheme 566

Special tools and workshop equipment required

1. Hinged Socket 3220
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Knurled Spacer Ring VAS 5161/23-1 and Guide Plate VAS 5161/23

Scheme 567

Special tools and workshop equipment required

1. Puller T10320
2. Camshaft Fitting Tool T40094
3. Camshaft Fitting Tool T40095
4. Component of T40096 T40096

Scheme 568

Special tools and workshop equipment required

1. Seal Puller - General Usage 2085
2. Retainer 3036
3. M10 x 1.25 x 40 hex bolt from Seal Installer 3241
4. Assembly Tool T10053
5. Puller T10320

Scheme 569

Special tools and workshop equipment required

1. Crankshaft Holder 3242
2. Diesel Injection Pump Locking Pin 3359
3. Key T40049
4. 3.3 mm diameter drill bit

Scheme 570

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 Knurled Spacer Ring VAS 5161/23-1 and Guide Plate VAS 5161/23
4. Engine and Transmission Holder VAS 6095
5. Cylinder Head Tensioning Device VAS 6419

Scheme 571

Special tools and workshop equipment required

Scheme 572

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

Scheme 582

1. Crankshaft Holder 3242
2. Socket T40058
3. Adjusting Pin T40060 (quantity: 2)
4. Adapter T40061
5. Adapter T40062
6. Hinged Socket 3220
7. Compression Tester V.A.G 1763 with Adapter V.A.G 1763/8
8. Dial Gauge Holder VW 387
9. Dial Gauge 0-10 mm VAS 6079
10. Socket T40058
11. Locking Pin T40071
12. Pry Lever - Rmv Outside Mirror 80-200
13. Retainer 3036
14. Hose Clamps Up to 25 mm Dia. 3094
15. Engine Bung Set VAS 6122
16. Puller T10320

See also:
• Description and Operation
• CLEAN WORKING CONDITIONS
• COOLANT PIPES OVERVIEW
• CRANKSHAFT SEAL, TRANSMISSION SIDE
• FASTENER TIGHTENING SPECIFICATIONS
• Removal and Installation
• Ignition/Glow Plug System
• OIL PUMP AND LOWER OIL PAN OVERVIEW
• LEFT INTERMEDIATE PIPE
• TURBOCHARGER OVERVIEW
• EXHAUST GAS RECIRCULATION OVERVIEW
• LEFT REAR COOLANT PIPE
• DRIVE PLATE
• RIGHT INTERMEDIATE PIPE
• INTERMEDIATE FLANGE
• SUBFRAME ASSEMBLY OVERVIEW
• UPPER OIL PAN OVERVIEW
• SEALING FLANGE, BELT PULLEY SIDE
• FUEL SYSTEM, CHECKING FOR LEAKS
• COOLING SYSTEM, DRAINING AND FILLING
• LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10
• UPPER RIGHT COOLANT PIPE
• PISTON PROJECTION, MEASURING AT TDC
• Description and Operation
• LEFT CYLINDER HEAD COVER
• RIGHT CYLINDER HEAD COVER
• CYLINDER HEAD
• CAMSHAFT SEAL
• LOWER TIMING CHAIN COVER
• LEFT TIMING CHAIN COVER
• RIGHT TIMING CHAIN COVER
• CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS
• CAMSHAFT TIMING CHAINS
• TIMING MECHANISM DRIVE CHAIN
• POWER TAKE-OFF DRIVE CHAIN
• BALANCE SHAFT
• VALVES, CHECKING
• VALVE DIMENSIONS
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS, CYLINDER HEAD INSTALLED
• VALVE STEM SEALS WITH CYLINDER HEAD REMOVED
• LEFT CYLINDER HEAD CAMSHAFT
• RIGHT CYLINDER HEAD CAMSHAFT
• CAMSHAFT, MEASURING AXIAL PLAY
• CAMSHAFT, MEASURING RADIAL PLAY
• HYDRAULIC ADJUSTING ELEMENTS, CHECKING
• CYLINDER HEAD COVER OVERVIEW
• CAMSHAFT TIMING CHAINS OVERVIEW
• CHECKING THE VALVE TIMING
• CYLINDER HEAD OVERVIEW