Audi Workshop Service and Repair Manuals

Installing cylinder head Special tools and workshop equipment required

t  Camshaft bar -T10068 A- Procedure   Note t  Renew the cylinder head bolts. t  On 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  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  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  The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head. t  When installing an exchange cylinder head, the contact surfaces between the hydraulic compensation elements, roller rocker fingers and cams must be oiled before installing the head. t  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. 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 coolant and engine oil. –  Set camshafts to TDC before fitting cylinder head.

–  Cams -A- of cylinder 1 must face each other.

–  Check TDC position of camshafts: l  You should be able to insert the camshaft bar -T10068 A- in the slots in both camshafts.

–  Check again whether the crankshaft is positioned at TDC -arrow-.

–  Fit cylinder head gasket. l  Note position of centring pins in cylinder block. l  Check installation position of cylinder head gasket; the Part No. should be legible from inlet side. –  Fit the cylinder head. –  Insert and hand-tighten cylinder head bolts.   Note The long cylinder head bolts are inserted in the middle bores in cylinder head. –  Tighten cylinder head bolts → Fig..   Note Cylinder head bolts do not have to be torqued down again later after repair work. –  Install camshaft timing chain → Anchor. –  Install cylinder head cover → Chapter. –  Install intake manifold → Rep. Gr.24. –  Change engine oil → Booklet808. –  Connect earth strap to battery → Rep. Gr.27. –  Fill cooling system with fresh coolant → Chapter. Tightening torque

Component	Nm
Front exhaust pipe to exhaust manifold	25 → Note

1)  Renew nuts