Audi Workshop Service and Repair Manuals

Removing and installing cylinder head Special tools and workshop equipment required

t  Puller -T40039- Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off. –  Drain off coolant → Chapter. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50. –  Remove starter catalytic converter → Chapter. –  Remove intake manifold → Rep. Gr.24. –  Remove coolant pipe (large) → Chapter. –  Remove coolant pipe (small) → Chapter.

–  Unplug electrical connector -arrow- at Hall sender -G40-.

–  Unscrew bolt -2- and remove bracket. –  Pull the guide tube for oil dipstick out upwards. –  Unplug electrical connector -1- at coolant temperature sender -G62-.

–  Unplug electrical connectors -3- and -4-.

–  Unplug electrical connector -arrow- at oil pressure switch -F1-.

–  Unplug connector -item 1- for inlet camshaft control valve 1 -N205- and -item 4- for fuel pressure regulating valve -N276-. –  Remove exhauster pump -3-.   Note Shown in illustration from rear with engine removed. –  Remove toothed belt from camshaft sprocket: t  Vehicles to 04.2003 → Chapter. t  Vehicles from 05.2003 to 05.2004 → Chapter. t  Vehicles from 06.2004 → Chapter.

–  Remove retaining plate for tensioning roller -arrows-, if fitted. –  Remove bolts -1-.

–  Remove bolts -1-. –  Unplug electrical connectors on ignition coils -2-.

–  Disconnect crankcase breather hoses -1- from cylinder head cover. –  Remove ignition coils -2-.   Note

Use puller -T40039- to remove ignition coils.

–  Unscrew cylinder head cover bolts in the sequence -14 ... 1-. –  Remove cylinder head cover.

–  Remove cylinder head bolts in the sequence: -1 ... 10-. –  Remove the cylinder head with the assistance of a 2nd mechanic. Installing   Note t  Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark plug thread can be re-installed without reducing service life, provided the cracks are only slight and do not exceed a maximum of 0.3 mm in width, and no more than the first 4 turns of the spark plug threads are cracked. 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, gaskets and O-rings. t  Renew. t  Carefully remove any sealant residue 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  When installing an exchange cylinder head with the camshafts fitted, the contact surfaces between bucket tappet and cam running surface must be oiled after installation of the cylinder head. t  The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head. 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  When fitting a new cylinder head or cylinder head gasket, drain off all the old coolant and refill with new coolant. t  Fit all cable ties in the original positions when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Set camshaft to TDC -top arrow- before fitting cylinder head. –  Make sure that crankshaft is in TDC position -bottom arrow-; turn crankshaft via central bolt on toothed belt sprocket if necessary.

–  Fit cylinder head gasket. l  Note position of centralising pins in cylinder block -arrows-. 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.

–  Tighten cylinder head bolts in 3 stages in the sequence indicated: 1.  Tighten with torque wrench to 40 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. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cylinder head cover → Anchor. –  Fit toothed belt: t  Vehicles to 04.2003 → Anchor. t  Vehicles from 05.2003 to 05.2004 → Anchor. t  Vehicles from 06.2004 → Anchor. –  Install poly V-belt → Chapter. –  Install coolant pipe (small) → Chapter. –  Install coolant pipe (large) → Chapter. –  Install exhauster pump → Rep. Gr.47. –  Install intake manifold → Rep. Gr.24. –  Install starter catalytic converter → Chapter. –  Align exhaust system so it is free of stress → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Connect battery. Procedures required → Electrical system; Rep. Gr.27. –  Check oil level → Chapter.   Note If engine oil is contaminated, perform oil change → Booklet803. –  Fill cooling system with fresh coolant → Anchor. Tightening torque

Component	Nm
Retaining plate for tensioning roller to cylinder head	9 1)
Guide tube bracket for oil dipstick to fuel rail	10
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue.