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Removing and installing intake manifold > < Removing cylinder head (right-side)

A4 Mk2

Installing cylinder head
Installing cylinder head
  Note
t  Renew the cylinder head bolts.
t  Renew self-locking nuts and bolts when performing assembly work.
t  Renew bolts which are tightened to a specified angle as well as oil seals and gaskets.
t  If repairing, carefully remove any remaining gasket material 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  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.
t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted.
t  Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks.
t  Position cylinder head gasket on dowel sleeves. The word “oben” (top) or the Part No. should face towards cylinder head.
t  When renewing a cylinder head, a sealing cap must be driven into the front of the cylinder head → Fig..
t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.
t  Renew all cable ties which are released or cut open when removing the engine. Refit in the same position when installing the engine.
t  After working on the valve gear, turn the engine carefully at least 2 rotations by hand to ensure that none of the valves make contact when the starter is operated.
Installation is carried out in the reverse order; note the following:
   
–  Before installing cylinder head, set crankshaft and camshafts to TDC:
l  The large holes -arrows- in the locating plates on the camshaft sprockets must be opposite one another on the inside.
  A13-0541
l  The locking pin -3242- must be screwed in.
  V13-0831
–  Fit cylinder head gasket.
l  Note position of centring pins -arrows- in cylinder block.
l  Check installation position of cylinder head gasket: the word “oben” (top) or the Part No. should face towards the cylinder head.
–  Fit cylinder head.
–  Insert new cylinder head bolts and tighten finger-tight.
  A15-0324
–  Tighten cylinder head bolts in 3 stages in the sequence indicated:
1.  Tighten with torque wrench to 60 Nm.
2.  Turn 90° (1/4 turn) further using a rigid wrench.
3.  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.
–  Install cylinder head cover: left-side → Chapter, right-side → Chapter.
–  Install toothed belt (adjust valve timing) → Anchor.
–  Install front exhaust pipe: left-side → Chapter, right-side → Chapter.
–  Align exhaust system so it is free of stress → Chapter.
–  Screw in centering pin for intake manifold.
–  Install intake manifold → Chapter.
–  Observe notes on procedures required after connecting battery → Electrical system; Rep. Gr.27.
–  Fill cooling system with fresh coolant → .
–  Top up power steering fluid and bleed steering system: → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.48
Tightening torques
  A15-0063
ComponentNm
Coolant pipe (rear) to cylinder head10
Combination valve to cylinder head10
Connecting pipe to combination valve10
Connecting pipeM610
to cylinder headM822
Hose connection to coolant pipe (rear)15
Coolant pipe (left-side) to cylinder head20
Coolant pipe (front)M610
to cylinder headM822
Guide tube for dipstick to cylinder head22
Pressure pipe for power steering to power steering pump47
Pressure pipe for power steering to cylinder head cover10
Toothed belt cover (rear)10 → Note

1)  Apply locking fluid to bolts; locking fluid → Parts catalogue.
   

Removing and installing intake manifold > < Removing cylinder head (right-side)