Audi Workshop Service and Repair Manuals

Notes:

• ◆ Replace cylinder head bolts.
• ◆ When carrying out repair work, replace oil seals and gaskets, self-locking nuts and anti-fatigue bolts tightened with an angle measuring wrench.
• ◆ Hose connections and hoses for charge-air system must be free from oil and grease before fitting.
• ◆ Secure all hose connections with standard hose clamps:

=> Parts List

• ◆ When performing repair work, carefully remove remnants of gasket from cylinder head and cylinder block. Take care to avoid scoring or scratches.
• ◆ Carefully remove abrasive and grinding residue.
• ◆ Do not remove new cylinder head gasket from wrapping until immediately prior to installation.
• ◆ Gasket is to be handled with extreme care. Damage to silicone coat and in bead area will lead to leakage.
• ◆ There must not be any oil or coolant in blind holes for cylinder head bolts in cylinder block.

Install in reverse order, paying attention to the following:

• ‒ Before mounting cylinder head, position crankshaft and camshaft to cylinder 1 TDC:
• ‒ → On the camshaft the cams for cylinder 1 must all point uniformly upwards -arrows- ...

• ‒ → ... and the crankshaft toothed belt must be locked with crankshaft stop T10050.

Note:

The markings on the toothed belt sprocket -2- and on the crankshaft stop -1- must face each other. The journal of the crankshaft stop must engage in the sealing flange hole.

• ‒ → Pay attention to marking of cylinder head gasket.
• ‒ Part no. = arrow 1
• ‒ Control code = arrow 2 (Ignore!)
• ‒ Holes = arrow 3

Notes:

• ◆ If the cylinder head gasket or cylinder head is replaced, select the new cylinder head gasket according to the number of holes in the old gasket.
• ◆ If parts of the crank gear have been replaced, the new cylinder head gasket must be redefined by measurement of the piston projection at TDC => Page 13-93.

• ‒ → Fit cylinder head gasket.
• ‒ Pay attention to centring bushes -arrows- in cylinder block
• ‒ Heed installation position of cylinder head gasket; "top" mark/part no. must face cylinder head

• ‒ Fit cylinder head.
• ‒ Check that all cylinder head bolt washers are inserted in cylinder head.
• ‒ Insert cylinder head bolts and screw in hand-tight.

• ‒ → Tighten the cylinder head in four stages as follows, in the order shown:
• ‒ Use torque wrench to tighten:
• ‒ 1. stage: 40Nm
• ‒ 2. stage: 60 Nm
• ‒ Use fixed wrench to tighten:
• ‒ 3. stage: 90°(1/4 turn) more)
• ‒ 4. stage: 90°(1/4 turn) more)

Note:

It is not necessary to re-tighten cylinder head bolts after repairs have been performed.

• ‒ Mount hub on camshaft.
• ‒ → Tighten bolt -1- to 100 Nm, bracing with counterhold T10051.

• ‒ → Push camshaft sprocket onto hub.

Note:

The tooth segment -arrow- of the camshaft sprocket must be at the top.

• ‒ Screw bolts -1- in hand-tight.
• ‒ Arrest hub with rig pin 3359.

• ‒ Install toothed belt (adjust valve timing) => Page 13-44.

Note:

Follow all instructions for removing and installing the toothed belt

=>from page 13-36.

• ‒ Install cylinder head cover => Page 15-12.
• ‒ Install ribbed belt =>Page 13-24.
• ‒ Install lock carrier =>Page 13-1.
• ‒ Perform stress-free alignment of exhaust system => Page 26-23.
• ‒ Check oil level.

Note:

Change oil if engine oil is contaminated.

=> Maintenance

• ‒ Replace coolant=> Page 19-11.

Note:

On re-connecting battery, remember to activate vehicle equipment (radio/radio navigation system, clock, electric window lifters) in line with owner's manual.

Tightening torques

    1)    Insert with locking fluid1;
        For locking fluid refer to

=> Parts List

    2)    Replace self-locking nuts