Audi TT (2007 year). Instruction - page 30
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Slacken cylinder head bolts in the sequence -1 ... 10-.
Note
♦
A second mechanic is required for removal of the cylinder
head.
♦
The toothed belt tensioning roller is detached from the stud
when the cylinder head is lifted out.
♦
The oil return line from the turbocharger is pulled out of the
support when the cylinder head is lifted out.
– Lift cylinder head at gearbox end first and guide out of toothed
belt cover. Make sure toothed belt tensioning roller does not
drop out.
– Take care to place cylinder head down without bending oil re‐
turn line. If necessary, place a block of wood below exhaust
manifold.
Caution
Risk of damage to glow plugs when putting down cylinder
head.
♦ After removal, the cylinder head must not be put down on
the gasket side with the glow plugs still installed, because
the glow plugs project slightly beyond the gasket surface.
Installing
• Tightening torques
⇒ page 100
2. Cylinder head
111
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Caution
Avoid damage to sealing surfaces.
♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Avoid damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Risk of leaks at cylinder head gasket.
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive ma‐
terial.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Avoid damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
Note
♦
Renew the bolts tightened with specified tightening angle.
♦
Renew self-locking nuts as well as seals, gaskets and O-rings.
♦
Cylinder heads must not be reworked on TDI engines.
♦
When installing an exchange cylinder head, the contact sur‐
faces between roller rocker fingers and cams must be oiled.
♦
Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦
To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
♦
After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.
112
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Before fitting cylinder head, remove crankshaft stop -T10050-
and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– To centralise, screw guide pins -3070/9- into outer holes on
inlet side.
– Note cylinder head gasket identification:
1 - Part number
2 - Holes
3 - Ignore
Note
♦
If the cylinder head gasket or cylinder head have been re‐
placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦
If parts of the crankshaft drive have been renewed, the new
cylinder head gasket must be selected by measuring the pis‐
ton projection at “TDC”
⇒ page 81
.
– Place cylinder head gasket in position.
• Note position of dowel sleeves in cylinder block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Fit cylinder head.
Note
Position tensioning roller on stud when fitting cylinder head.
– Screw in 8 cylinder head bolts by hand until they make contact.
– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw in remaining cylinder head bolts by hand until
they make contact.
2. Cylinder head
113
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Tighten cylinder head bolts
⇒ page 102
.
Note
Cylinder head bolts do not have to be torqued down again.
– Install rear cover for toothed belt, camshaft hub and sprocket
⇒ page 84
.
– Lock camshaft hub with diesel injection pump locking pin
-3359- .
Note
Disregard items marked -1- and -arrow-.
– Lock high-pressure pump hub with diesel injection pump lock‐
ing pin -3359- .
Note
Disregard -item 1-.
114