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Audi A4 Workshop Service and Repair Manuals

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Removing and installing cylinder head > < Cylinder head

A4 Mk3 Power Unit: 4-Cylinder Direct Injection Engine Cylinder Head - Exploded View

Cylinder head - exploded view
Cylinder head - exploded view
  Note
t  Renew the cylinder head bolts.
t  During assembly, renew oil seals and gaskets as well as self-locking nuts and bolts that are tightened by turning through to a specified angle.
t  The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.
t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and coolant.
   
1 - Cylinder head gasket
q   Renew
q   Note installation position: part number must face cylinder head
2 - Bolt
q   Renew
q   Note procedure when loosening → Fig.
q   Note procedure when tightening → Fig.
3 - Cylinder head
q   Removing and installing → Chapter
q   Checking for distortion → Fig.
4 - Cylinder head bolt
q   Renew
q   Note procedure when loosening → Fig.
q   Note procedure when tightening → Fig.
5 - Heat shield
6 - Bolt
q   9 Nm
7 - Cylinder head cover
q   With integrated camshaft bearings
q   Clean sealing surface; machining not permitted
q   Remove old sealant residues
8 - O-ring
q   Renew
q   Lubricate with engine oil
9 - Hall sender 3 -G300-
10 - Bolt
q   9 Nm
11 - Sealing plug
q   5 Nm
q   With ball head for engine cover panel
12 - Gasket
q   Renew if damaged
13 - Vacuum pump
q   Removing and installing → Rep. gr.47
14 - Bolt
q   Tightening torque → Rep. gr.47
15 - Coolant temperature sender -G62-
16 - Bolt
q   9 Nm
17 - O-ring
q   Renew
q   Lubricate with coolant
18 - Bolt
q   9 Nm
19 - Connection
20 - O-ring
q   Renew
q   Lubricate with coolant
21 - Transport plate
22 - Bolt
q   25 Nm
23 - Hall sender -G40-
24 - Bolt
q   9 Nm
25 - O-ring
q   Renew
q   Lubricate with engine oil
26 - Transport plate
27 - Bolt
q   25 Nm

   
Slackening cylinder head bolts
–  Remove bolts -arrows-.
–  Slacken cylinder head bolts in the sequence -1 ... 10-.
  A15-11209
Tightening sequence for cylinder head
–  Tighten cylinder head bolts in the sequence -1 ... 10- as follows:
1.  Tighten with torque wrench initially to 40 Nm.
2.  Use rigid wrench to turn 90° further.
3.  Use rigid wrench to turn 90° further.
4.  Pre-tighten bolts -arrows- to 8 Nm.
5.  Turn bolts -arrows- 90° further using a rigid wrench.
  A15-11210
Checking cylinder head for distortion
–  Use straight edge and feeler gauge to measure cylinder head for distortion at several points.
t  Max. permissible distortion: 0.05 mm
  V15-0654
1 - Cylinder head gasket
q   Renew
q   Note installation position: part number must face cylinder head
2 - Cylinder head bolt
q   Renew
q   Note procedure when loosening → Fig.
q   Note procedure when tightening → Fig.
3 - Sealing cap
q   With seal
4 - O-ring
q   Renew
q   Lubricate with engine oil
5 - Sealing plug
6 - Bolt
q   20 Nm
7 - Bolt
q   20 Nm
8 - Breather pipe
9 - Engine cover panel
10 - Bolt
q   Tightening sequence → Fig.
11 - Crankcase breather
12 - Gasket
q   Not available as replacement part
13 - Bracket
14 - Bolt
q   9 Nm
15 - O-ring
q   Renew
q   Lubricate with coolant
16 - Bolt
q   9 Nm
17 - Hall sender -G40-
18 - Separating plate
19 - O-ring
q   Renew
q   Lubricate with engine oil
20 - Actuator for variable valve timing
21 - 

   
Crankcase breather system - tightening torque
  Note
t  The bolts are thread-forming bolts. When renewing the cylinder head, it is important that you use only genuine bolts since the cylinder head is supplied without threaded holes for attachment of the crankcase breather.
t  Do NOT make threaded holes using a thread tap.
t  Tighten bolts for crankcase breather system in the sequence -1 ... 10- to 11 Nm.
  A15-10605

Removing and installing cylinder head > < Cylinder head