Audi Workshop Service and Repair Manuals

Installing cylinder head Special tools and workshop equipment required

t  Locking pin -3242-

t  Camshaft holder -3458- Procedure Installation is carried out in the reverse order; note the following:   Caution Avoid damage to sealing surfaces. t  Carefully remove sealant residue from cylinder head and cylinder block. t  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. t  Carefully remove any sealant residue from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. t  Carefully remove any remaining emery and abrasive material. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  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 engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts as well as seals, gaskets and O-rings. t  Cylinder heads must not be reworked on TDI engines. t  When installing an exchange cylinder head with camshafts fitted, the contact surfaces between the hydraulic compensation elements, roller rocker fingers and cams must be oiled. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and coolant.

–  Before installing cylinder head, set crankshaft and camshafts to “TDC”: l  It should be possible to insert camshaft holder -3458- into camshaft.

l  Locking pin -3242- must be screwed in with crankshaft at “TDC” position.

–  Note identification markings on cylinder head gasket. 1 -  Holes 2 -  Part number 3 -  Production code (can be disregarded)   Note t  If the cylinder head gasket or cylinder head have been replaced, select the new cylinder head gasket according to the number of holes on the old gasket. t  If parts of the crankshaft drive have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at “TDC” → Chapter. –  Renew O-rings for coolant pipe before installing cylinder head. –  Place cylinder head gasket in position. l  Note position of centring pins in cylinder block. l  Note installation position of cylinder head gasket: the word “oben” (top) or the part number should face towards the cylinder head.

–  Fit cylinder head. –  Tighten bolts in the sequence -1 ... 8- in 5 stages as follows: 1.  Screw in by hand until they make contact. 2.  Tighten to 35 Nm. 3.  Tighten to 60 Nm. 4.  Turn 90° further. 5.  Turn 90° further.   Note Cylinder head bolts do not have to be torqued down again later after repair work. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cylinder head cover: left-side → Chapter; right-side → Chapter. –  When installing right cylinder head, renew O-ring at base of dipstick guide tube. To do this, take off poly V-belt, loosen alternator mounting bolts and pivot alternator to the side. –  Fit toothed belt onto camshaft sprockets (adjust valve timing) → Anchor.   Note Follow all instructions for removing and installing toothed belt → Chapter. –  Install exhaust manifold with intermediate pipe: left-side → Chapter, right-side → Chapter. –  Align the exhaust system free of stress: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Change engine oil → Booklet802.   Caution Risk of irreparable damage to injection pump. Do not attempt to start the engine without first bleeding the fuel system! –  Bleed fuel system → Rep. Gr.20. –  Observe notes on procedures required after connecting battery → Rep. Gr.27. –  Fill cooling system with fresh coolant → Anchor. –  Check fuel system for leaks → Chapter. Tightening torques

Component			Nm
Guide tube for dipstick to cylinder head			10
Toothed belt cover to	Cylinder head		10
	Injection pump		10
Coolant pipe (front) to cylinder head/cylinder block		M6	10
		M8	22
Oil pipe to:	Turbocharger		15
	Intake manifold		22
Heat shield to turbocharger			10
Coolant pipe (left-side) to cylinder head			10
Coolant pipe to intermediate flange			22
Mechanical exhaust gas recirculation valve to intake manifold			22