Audi Workshop Service and Repair Manuals

Notes:

• ◆ Replace the cylinder head bolts.
• ◆ When performing installation procedures always replace self-locking nuts and bolts.
• ◆ Replace seals, gaskets, and bolts which have a specified tightening angle.
• ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly.
• ◆ Secure all hose connections with the correct hose clamps (same as original equipment):

=> Parts List

• ◆ If repairing, carefully remove any remains of gasket material from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces.
• ◆ Carefully remove any remaining emery and abrasive material.
• ◆ Remove new cylinder head gasket from packaging, just before installation.
• ◆ Handle gasket extremely carefully. Damaging the silicone layer 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 head.

Installation is carried out in the reverse order; note the following:

• ‒ → The cams for cylinder 1 must point upwards evenly on camshaft -arrows-...

• ‒ → ...and the toothed belt sprocket crankshaft must be locked with the crankshaft stop T10050.

Note:

The markings on the toothed belt sprocket -2- and crankshaft stop -1- must align. The journal of the crankshaft stop must engage in the bore of the sealing flange.

• ‒ → Note markings on cylinder head gasket.

• ◆ Part-No. = arrow 1
• ◆ Production control code = arrow 2 (can be disregarded.)
• ◆ Holes = arrow 3

Notes:

• ◆ If the cylinder head gasket or the cylinder head has been replaced, select a new gasket according to the number of holes on the old gasket.
• ◆ If parts of the crank assembly have been replaced, the new cylinder head gasket must be selected by measuring the piston projection at TDC => Page 13-117.

• ‒ → Place cylinder head gasket in position.
• ‒ Note position of centring pins-arrows- in cylinder block.
• ‒ Check installation position of cylinder head gasket: mark "top" or the part No. must face cylinder head.

• ‒ Position cylinder head.
• ‒ Check that all the washers -15-88 are fitted in cylinder head.
• ‒ Insert cylinder head bolts and tighten by hand.

• ‒ → Tighten cylinder head bolts in four stages in sequence shown as follows:
• ‒ Tighten using torque wrench:
• ‒ 1st stage: 40 Nm
• ‒ 2nd stage: 60 Nm
• ‒ Tighten with rigid wrench:
• ‒ 3st stage: 90°(1/4 turn) further
• ‒ 4nd stage: 90°(1/4 turn) further

Note:

It is not necessary to retighten cylinder head bolts after repairs have been performed.

• ‒ Attach hub to camshaft.
• ‒ → Tighten the bolt -1- to 100 Nm. For this counterhold with T10051.

• ‒ → Push camshaft sprocket onto hub.

Note:

The spline -arrow- of the camshaft sprocket must face upwards.

• ‒ Screw in bolts -1- loosely.
• ‒ Lock the hub with mandrel 3359.
• ‒ Install toothed belt (adjust valve timing) => Page 13-62.

• ‒ Install cylinder head cover => Page 15-10.
• ‒ Install right drive shaft:

=> Running Gear, Front and Four-wheel Drive; Repair group 40; Servicing front drive shafts

• ‒ Install exhaust system and align it stress-free => Page 26-35.
• ‒ Install ribbed belt =>Page 13-12.

Notes:

• ◆ If the battery is reconnected, please ensure that the vehicle equipment (radio, radio/navigation system, clock, electric window lifters) is activated as described in the operating instructions.
• ◆ Deactivate the service mode of the telematics control unit.

=> Radio, Telephone and Navigation System; Repair group 91

• ‒ Check oil level => Page 17-23.

Note:

When engine oil is contaminated perform oil change:

=> Maintenance Manual

• ‒ Replace coolant => Page 19-10.

Tightening torques

    1)    install using locking compound;
        locking compound

=> Parts List