Installing cylinder head: Audi A3 (ACK, AEB, AFB, AFN, …)

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Opens: coolant
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: 3359, torque wrench
• Also covered elsewhere: Electronic parts catalogue

Don't miss

• The markings on the toothed belt sprocket and the crankshaft stop must align (arrow).
• The support hooks and retaining pins on the lifting tackle must be secured with locking pins (arrows). — Slightly lift cylinder head using workshop hoistVAS 6100.
• Cylinder head bolts do not have to be torqued down again later after repair work.
• Before installing rocker arm shaft, check that all ball studs (1) and O-rings (2) are fitted in unit injectors.
• Tighten securing bolt (1) to 100 Nm (use counterhold tool T10051).

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Check whether both the camshafts and the crankshaft are positioned at TDC: [Note: The markings on the toothed belt sprocket and the crankshaft stop must align (arrow).]
2. Check whether there is a slit dowel sleeve inserted between cylinders 1 and 2 (arrow A); insert if necessary.
3. Check which type of dowel sleeve is inserted between cylinders 3 and 4 (arrow B):
4. Pull closed dowel sleeve (arrow B) out of cylinder block and remove any remaining sealant.
5. Blow out drilled holes for dowel sleeve in cylinder block (1) and in cylinder head (3) with compressed air.

6. Clean and degrease each drilled hole down to a depth of 10 mm.
7. Allow holes to dry for 3 minutes and then coat drilled holes in cylinder block and cylinder head all around with sealantD 154 103 A1(item 5).
8. Insert closed dowel sleeve (4).
9. Note identification markings on cylinder head gasket. [Note: If the cylinder head gasket or cylinder head is renewed, be sure to install a gasket with the same identification.If parts of the crankshaft drive have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at TDC .]
10. Fit cylinder head gasket onto dowel sleeves (arrows) in cylinder block.
11. Fit cylinder head onto cylinder block.
12. Attach lifting tackle2024 A at cylinder head.
13. ⚠ The support hooks and retaining pins on the lifting tackle must be secured with locking pins (arrows). — Slightly lift cylinder head using workshop hoistVAS 6100.
14. Swivel cylinder head so that stud for toothed belt tensioner is inserted into aperture in toothed belt cover (rear) and attach tensioning roller at the same time.
15. Fit cylinder head onto cylinder block.
16. Insert and hand-tighten cylinder head bolts.
17. Tighten cylinder head bolts in 4 stages in the sequence shown:
18. Tighten with torque wrench to 40 Nm. — 40 Nm (30 lb-ft)
19. Tighten with torque wrench to 60 Nm. — 60 Nm (44 lb-ft)
20. Turn 90° (1/4 turn) further using a rigid wrench.
21. Turn 90° (1/4 turn) further using a rigid wrench. [Note: Cylinder head bolts do not have to be torqued down again later after repair work.]
22. Before installing rocker arm shaft, check that all ball studs (1) and O-rings (2) are fitted in unit injectors.
23. Secure the rocker arm shaft as follows:
24. Tighten bolts (2) and (4) alternately in several stages until rocker arm shaft lies on bearing frame.
25. Tighten bolts (1), (3) and (5) to 20 Nm + 90° (1/4 turn). — 20 Nm (15 lb-ft) + 90°
26. Tighten bolts (2) and (4) to 20 Nm + 90° (1/4 turn). — 20 Nm (15 lb-ft) + 90°
27. Tighten bolts (6 ... 10) to 20 Nm. — 20 Nm (15 lb-ft)
28. Apply locking fluid to bolts (2 … 5) and tighten bolts; for locking fluid refer to Electronic parts catalogue.
29. Screw nut (1) for toothed belt tensioner onto stud for toothed belt tensioner.
30. Attach hub to exhaust camshaft.
31. Tighten securing bolt (1) to 100 Nm (use counterhold tool T10051). — 100 Nm (74 lb-ft)
32. Attach hub to inlet camshaft.
33. Tighten securing bolt (1) to 100 Nm (use counterhold tool T10051). — 100 Nm (74 lb-ft)
34. Push camshaft sprockets onto hubs.
35. Screw in bolts (1) finger-tight.
36. Lock hubs with locking pins 3359.
37. Install toothed belt (adjust valve timing): vehicles with small engine support , vehicles with large engine support
38. Install vibration damper .
39. Install poly V-belt .
40. Install support for turbocharger: vehicles with engine codes AZV, BKD , vehicles with engine codes BMN, BUY .
41. Install cylinder head cover: vehicles with engine codes AZV, BKD , vehicles with engine codes BMN, BUY .
42. Install front exhaust pipe .
43. Install flange shaft (right-side) 39.
44. Install particulate filter .
45. Install exhaust system and align it free of stress .
46. Install drive shaft (left-side) 40.
47. Install air pipes: vehicles with engine codes AZV, BKD , vehicles with engine codes BMN, BUY .
48. Connect battery. Procedures required 27.
49. Change engine oil 808.
50. Fill cooling system with fresh coolant .

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