Audi Workshop Service and Repair Manuals

Notes:

• ◆ Always renew cylinder head bolts when assembling.
• ◆ When performing repairs, renew self-locking nuts and bolts.
• ◆ Renew self-locking nuts and bolts which have a specified tightening angle as well as seals and gaskets.
• ◆ Secure all hose connections with the correct hose clips (same as original equipment)

=> Parts catalogue

• ◆ 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 block.

• ‒ → Align marking on camshaft sprocket with marking on cylinder head cover -arrows-.

• ‒ Check again whether the crankshaft is positioned at TDC for cylinder 1:
• ‒ → Vehicles with manual gearbox

• ‒ → Vehicles with automatic gearbox

• ‒ → Place cylinder head gasket in position.
• ‒ Note position of centralizing pins in cylinder block -arrows-.
• ‒ Check installation position of cylinder head gasket. The part No. faces towards cylinder head and should be legible from inlet side.
• ‒ Place cylinder head on.

• ‒ Insert cylinder head bolts and tighten by hand.
• ‒ → Tighten cylinder head bolts in two stages in the sequence shown as follows:
• ‒ Tighten using torque wrench:
• ‒ 1st stage: 40 Nm
• ‒ Tighten with normal fixed wrench:
• ‒ 2nd stage: turn an additional 180° (1/2 turn)
  (alternatively 2 x 90° is possible)

Note:

It is not necessary to re-tighten cylinder head bolts later after repairs have been performed.

• ‒ Install cylinder head cover .
• ‒ Install toothed belt (adjust valve timing)
• ‒ Install upper section of intake manifold => Page 15-15.
• ‒ Check oil level => Page 17-22.

Note:

Change engine oil if dirty:

=> Maintenance booklet

• ‒ Install support for exhaust manifold.
• ‒ Install front exhaust pipe => Page 26-17.
• ‒ Aligning exhaust system free of stress =>
  Page 26-18.
• ‒ Fill up with coolant=> Page 19-7.

Notes:

• ◆ When the battery is reconnected, re-activate electrical equipment (radio, combined radio/navigation system, clock, electric windows) as described in the Owner's Manual.
• ◆ De-activate service mode in telematics control unit.

=> Radio, telephone and navigation system; Repair group 91

• ◆ Further procedures after reconnecting the voltage supply:

=> Motronic injection and ignition system; Repair group 24

Tightening torques