Audi Workshop Service and Repair Manuals

Notes:

• ◆ Cylinder heads with cracks between the valve seats can be used without reducing the service life if the cracks are small and a maximum of 0.5 mm wide.
• ◆ When fitting a new cylinder head or cylinder head gasket, drain off all the old coolant and re-fill with new coolant.
• ◆ When engine oil is contaminated perform oil change:

=> Maintenance Manual

• ◆ The cylinder head on a diesel engine must not be reworked.
• ◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between tappets and cams must be oiled after installing the head.
• ◆ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.
• ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly.

• Cylinder head gasket
• ◆ Renew => Removing cylinder head, Page 15-19.
• ◆ Observe marking
  => Fig.15-6
• ◆ After replacing, fill with fresh coolant
• 20 Nm
• Cylinder head
• ◆ Removing
• ◆ Checking for distortion
  => Fig.15-6
• ◆ Installing
• ◆ After replacing, fill with fresh coolant
• Lifting eye
• Cylinder head bolt
• ◆ Replace
• ◆ Note sequence when loosening => Page 15-34
• ◆ Note sequence when tightening => Page 15-39

• Oil deflector
• ◆ Bolted to cylinder head cover as of 10.97 (tightening torque 5 Nm)
• Cylinder head cover
• ◆ With gasket vulcanised in place
• ◆ Handle gasket with care
• ◆ Replace cylinder head cover if gasket is damaged
• ◆ Removing and installing
  .
• Sealing collar
• Cap
• ◆ Renew seal if damaged
• Vent pipe
• ◆ To rear air duct pipe
• Hose clamp

• Pressure regulating valve
• ◆ For crankcase breather
• Rubber grommet
• ◆ Replace if damaged
• Collared nut - 10 Nm
• ◆ Is tightened on block
• ◆ If tightening on block is not accomplished, oil contact surface
• ◆ Cylinder head cover mounting changed as of 10.97 => Page 15-10
• Sealing washer, upper
• ◆ Replace if damaged
• ◆ Cylinder head cover mounting changed as of 10.97 => Page 15-10
• Sealing cone, lower
• ◆ Cylinder head cover mounting changed as of 10.97 => Page 15-10

• Injector pipes
• ◆ Tighten to 25 Nm
• ◆ Remove using 3035
• ◆ Always remove pipework as a complete unit
• ◆ Do not alter shape
• Exhauster
• ◆ For brake servo
• ◆ Removing and installing => Fig.15-8
• 20 Nm
• Gasket
• ◆ Replace

→ Fig.1    Check cylinder head for distortion.

• ‒ Use knife edge, straightedge and feeler gauge to measure at several points.
• ‒ Max. permissible distortion: 0.1 mm

Note:

The cylinder head on a diesel engine must not be reworked.

→ Fig.2    Cylinder head gasket-marking

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

Note:

Cylinder head gaskets of different thicknesses are fitted depending on the amount of piston projection => Page 13-79. When replacing just the gasket, the new gasket should have the same markings.

→ Fig. 3    Seal connections between bearing cap and cylinder head

• ‒ Coat both edges on the sealing edges of bearing cap/cylinder head -arrows- on front...

• ‒ → ... and apply a drop of sealing fluid at rear (ø approx. 5 mm) -arrows-.
• ‒ Sealants

=> Parts List

→ Fig.4    Removing and installing exhauster pump

• ‒ Where present, unscrew the vacuum hose bracket from the dual bolt -2- and -3-.
• ‒ Disconnect the vacuum hose -arrow- from the brake servo.
• ‒ Screw out bolts -1 ... 3- and remove the exhauster.

Tightening torque