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

Mechanical 19 illustrations ~1732 words

CYLINDER HEAD COVER OVERVIEW

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

Scheme 437

Scheme 437: CYLINDER HEAD COVER OVERVIEW
Scheme 437: CYLINDER HEAD COVER OVERVIEW
  1. Cylinder Head Cover Gasket Replace if damaged or leaking
  2. Cylinder Head Cover Removing and installing, refer to LEFT CYLINDER HEAD COVER and 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
  10. High-Pressure Line Note rules of cleanliness, refer to CLEAN WORKING CONDITIONS Mark the order of the injectors Do not change bent shape Installing, refer to Description and Operation
  11. Fuel Return Line Note rules of cleanliness, refer to CLEAN WORKING CONDITIONS
  12. O-ring Replace
  13. Bolt Tightening specifications, refer to Description and Operation
  14. Tensioning Bracket
  15. Screw 5 Nm
  16. Bracket For the electrical connectors
  17. Injector Note rules of cleanliness, refer to CLEAN WORKING CONDITIONS Removing and installing, refer to Removal and Installation
  18. Bolt 5 Nm
  19. Bracket For the electrical wiring harness
  20. O-ring Replace
  21. Copper Sealing Ring Replace

Scheme 438

Scheme 438
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

Scheme 439: CYLINDER HEAD OVERVIEW
Scheme 439: CYLINDER HEAD OVERVIEW
  1. Cylinder Head Gasket Removing and installing, refer to CYLINDER HEAD 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
  3. Bolt Tightening specifications, refer to Description and Operation
  4. High Pressure Pump Toothed Belt Drive Sprocket Removing and installing, refer to Removal and Installation
  5. Rear Toothed Belt Guard
  6. Camshaft Seal Removing and installing, refer to CAMSHAFT SEAL
  7. Seals Replace
  8. Banjo Bolt Tightening specifications, refer to "Banjo Bolt" in numbered list under COOLANT PIPES OVERVIEW
  9. Fuel Rail Note rules of cleanliness, refer to CLEAN WORKING CONDITIONS Removing and installing, refer to Removal and Installation Do not change the angles of the high pressure lines High pressure lines, removing and installing, refer to Removal and Installation
  10. Bolt Tightening specifications, refer to Description and Operation
  11. Coolant Pipe
  12. Bolt Replace Loosening sequence LOOSEN THE CYLINDER HEAD BOLTS IN THE FOLLOWING SEQUENCE -1 THROUGH 8 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 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

Scheme 440
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

Scheme 441
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

Scheme 442
Scheme 442

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

Tighten the bolts in 5 steps according to the tightening sequence

StepBoltsTightening Torque/Additional Angle of Rotation
1.1 through 8Install all the way in by hand.
2.1 through 835 Nm
3.1 through 860 Nm
4.1 through 8Tighten an additional 90°.
5.1 through 8Tighten an additional 90°.

TIMING CHAIN COVERS OVERVIEW

Vehicles Built through 05.10

Scheme 443

Scheme 443: TIMING CHAIN COVERS OVERVIEW
Scheme 443: TIMING CHAIN COVERS OVERVIEW
  1. Crankshaft Shaft Seal, Transmission Side Removing and installing, refer to CRANKSHAFT SEAL, TRANSMISSION SIDE
  2. Lower Timing Chain Cover Removing and installing, refer to 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
  10. Gasket Replace
  11. Bolt Replace Tightening specification and sequence (Scheme 446)
  12. Bolt Tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS
  13. Vacuum Pump Removing and installing, refer to Removal and Installation
  14. O-rings Replace
  15. Right Timing Chain Cover Removing and installing, refer to 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

Scheme 444
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
  4. Lower Timing Chain Cover Removing and installing, refer to 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
  12. Gasket Replace
  13. Bolt Replace Tightening specification and sequence (Scheme 446)
  14. Bolt Tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS
  15. Vacuum Pump Removing and installing, refer to Removal and Installation
  16. O-rings Replace
  17. Right Timing Chain Cover Removing and installing, refer to 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
  25. Engine Speed (RPM) Sensor -G28- Removing and installing, refer to Ignition/Glow Plug System

Scheme 445

Scheme 445
Scheme 445

Tighten bolts in 4 stages as follows

StepBoltsTightening Specification
1.13 Nm
2.29 Nm
3.19 Nm
4.39 Nm in a diagonal sequence

Scheme 446

Scheme 446
Scheme 446

Tighten bolts in 4 stages as follows

StepBoltsTightening Specification
1.13 Nm
2.29 Nm
3.19 Nm
4.39 Nm in a diagonal sequence

Scheme 447

Scheme 447
Scheme 447

Tighten the bolts in 3 steps according to the tightening sequence

StepBoltsTightening Specification
1.1 through 95 Nm from the inside toward the outside and diagonally
2.1 through 79 Nm from the inside toward the outside and diagonally
3.8- and -923 Nm

CAMSHAFT TIMING CHAINS OVERVIEW

Left Camshaft Timing Chain

Scheme 448

Scheme 448: CAMSHAFT TIMING CHAINS OVERVIEW
Scheme 448: CAMSHAFT TIMING CHAINS OVERVIEW
  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 Before removing, mark the direction of rotation with paint Removing and installing, refer to 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

Scheme 449
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 Before removing, mark the direction of rotation with paint Removing and installing, refer to 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

Scheme 450: TIMING MECHANISM DRIVE CHAIN OVERVIEW
Scheme 450: TIMING MECHANISM DRIVE CHAIN OVERVIEW
  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
  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

Scheme 451: POWER TAKE-OFF DRIVE CHAIN OVERVIEW
Scheme 451: POWER TAKE-OFF DRIVE CHAIN OVERVIEW
  1. Power Take-Off Drive Chain Removing and installing, refer to 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
  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

Scheme 452: BALANCE SHAFT OVERVIEW
Scheme 452: BALANCE SHAFT OVERVIEW
  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

VALVETRAIN OVERVIEW

CAUTIONRisk of damaging valves and piston heads after working on valvetrain. The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves. To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.

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

Scheme 453

Scheme 453
Scheme 453
  1. Valve Do not reface, only lapping is permitted Mark the installed position for installation later Checking, refer to VALVES, CHECKING For the correct valve dimensions, refer to VALVE DIMENSIONS
  2. Cylinder Head Valve guides, checking, refer to 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 and VALVE STEM SEALS WITH CYLINDER HEAD REMOVED
  4. Valve Spring
  5. Valve Spring Plate
  6. Valve Retainers
  7. Camshaft Seal Removing and installing, refer to 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 and RIGHT CYLINDER HEAD CAMSHAFT
  11. Intake Camshaft Removing and installing, refer to LEFT CYLINDER HEAD CAMSHAFT and RIGHT CYLINDER HEAD CAMSHAFT Measuring axial play, refer to CAMSHAFT, MEASURING AXIAL PLAY Radial clearance, measuring, refer to CAMSHAFT, MEASURING RADIAL PLAY Maximum run out: 0.01 mm
  12. Exhaust Camshaft Removing and installing, refer to LEFT CYLINDER HEAD CAMSHAFT and RIGHT CYLINDER HEAD CAMSHAFT Measuring axial play, refer to CAMSHAFT, MEASURING AXIAL PLAY Radial clearance, measuring, refer to CAMSHAFT, MEASURING RADIAL PLAY Maximum run out: 0.01 mm
  13. Roller Rocker Lever Removing and installing, refer to LEFT CYLINDER HEAD CAMSHAFT, 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 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

Scheme 454
Scheme 454

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

StepBolts/NutsTightening Specification
1.1 through 18Install all the way in by hand. The guide frame must be in contact with the entire contact surface of the cylinder head.
2.1 through 189 Nm

Scheme 455

Scheme 455
Scheme 455

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

StepBolts/NutsTightening Specification
1.1 through 17Install all the way in by hand. The guide frame must be in contact with the entire contact surface of the cylinder head.
2.1 through 179 Nm

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