Cylinder Head, Installing Audi TT 8N

Special tools, testers and auxiliary items required

1. Camshaft bar T10068

Note. Replace cylinder head bolts. On assembly, replace self-locking nuts and bolts that are tightened by turning through to a specified angle, as well as oil seals and gaskets. Secure all hose connections with the correct type of hose clamps (same as original equipment). If repairing, carefully remove any remaining gasket material from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. Do not remove new cylinder head gasket from packaging until it is ready to be installed. Handle the gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.

1. Set camshafts to TDC for cylinder No. 1 before installing cylinder head.

1. It must be possible to insert camshaft plate T10068 in both camshaft grooves.

1. Check again whether crankshaft is positioned at TDC (arrow).

Scheme 165

1. Install new cylinder head gasket.
2. Pay attention to centering pins in cylinder block.
3. Check installed position of cylinder head gasket; Part No. must be visible from intake side.
4. Install cylinder head.

1. Insert cylinder head bolts and tighten by hand.

Note. The long cylinder head bolts are inserted in the middle bores in the cylinder head.

1. Tighten cylinder head in 4 stages in following sequence
2. Tighten using a torque wrench

1. 1st stage: 30 Nm
2. 2nd stage: 50 Nm

1. Tighten with a Torx key

1. 3rd stage: 90° (1/4 turn) further
2. 4th stage: 90° (1/4 turn) further

Note. Re-tightening of the cylinder head bolts is not necessary on completion of repair work.

1. Install camshaft timing chain. Refer to «Camshaft timing chain, removing from camshafts»(ref-276269-S22252894662008010300000) .
2. Install cylinder head cover. Refer to «Cylinder head cover, removing and installing»(ref-276269-S10542814972008010300000) .
3. Install intake manifold. Refer to «Intake manifold, removing and installing»(ref-276269-S38653353982008010300000) .
4. Replace coolant. Refer to «Cooling system, draining and filling»(ref-276269-S04050758062008010300000) .

1. Connect Ground strap to battery

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tightening torque

1) Replace nuts

Scheme 166

Special tools and equipment required

1. Spark plug socket 3122 B
2. Compression tester V.A.G 1763
3. Puller T10095 A
4. Assembly tool T10118

Conditions

1. Engine oil temperature at least 30° C
2. Battery voltage at least 12.7 V

Work sequence

1. Switch off ignition.

Scheme 167

1. Remove fuel pump fuse from slot No. 28.

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

1. Attach puller T10095 A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.
2. Remove spark plugs with spark plug wrench 3122 B.
3. Check compression pressure with compression tester V.A.G 1763.

Note. For use of compression tester. Refer to tester operating instructions.

1. Have a second technician press down accelerator pedal completely and simultaneously operate starter until pressure no longer increases on tester display.

Compression pressure

Installation is performed in the reverse order. Note the following

1. Upon completion of compression test, interrogate and erase engine control module fault memory. Faults will have been stored during fuse removal and connector separation. Use vehicle diagnostic, testing and information system VAS 5051 A.

Tightening torque