Audi Workshop Service and Repair Manuals

Installing cylinder head Special tools and workshop equipment required

t  Locking pin -3242-

t  Camshaft clamp -3458- Procedure   Note 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  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  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  Position cylinder head gasket on dowel sleeves. The word “oben” (top) or the Part No. should face towards the cylinder head. t  The plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. t  When installing an exchange cylinder head with fitted camshafts, oil the contact surfaces between the rocker fingers and cams. t  After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Set crankshaft and camshaft to TDC before fitting cylinder head.

l  It should be possible to insert camshaft clamp -3458- into camshaft.

l  Locking pin -3242- must be screwed in with crankshaft at TDC position.

–  Note identification markings on cylinder head gasket. -Arrow 1- = holes -Arrow 2- = Part No. -Arrow 3- = production control code (can be disregarded)   Note t  If the cylinder head gasket or cylinder head have been replaced, select the new cylinder head gasket according to the number of holes on the old gasket. t  If parts of the crankshaft drive have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at TDC → Chapter. –  Renew O-rings for coolant pipes before installing cylinder head. –  Fit cylinder head gasket. l  Note position of centring pins in cylinder block. l  Check installation position of cylinder head gasket: the word “oben” (top) or the Part No. should face towards the cylinder head. –  Fit the cylinder head. –  Insert new cylinder head bolts and tighten finger-tight.

–  Tighten cylinder head bolts as follows in the sequence shown: Tighten using torque wrench: 1.  stage: 35 Nm 2.  stage: 60 Nm Tighten using rigid spanner: 3.  stage: 90° (1/4 turn) further 4.  stage: 90° (1/4 turn) further   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: left-side → Chapter, right-side → Chapter. –  When installing right cylinder head, renew O-ring at base of dipstick guide tube. To do this, take off poly V-belt, loosen alternator mounting bolts and pivot alternator to the side. –  Install coolant pipe (right-side) → Chapter. Vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC: –  Install coolant pipe (top and bottom left) → Chapter. Vehicles with engine code letters BDG, BDH: –  Install coolant pipe (top left) → Chapter. –  Install coolant pipe (bottom left) → Chapter. All vehicles: –  Install coolant pipe (front) → Chapter. –  Install exhaust manifold together with intermediate pipe: left-side → Chapter, right-side → Chapter. –  Install starter catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Install front exhaust pipe with main catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Install intake manifold (front section) → Rep. Gr.23. –  Install toothed belt (adjust valve timing) → Anchor. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Fill cooling system → Anchor. –  Observe notes on procedures required after connecting battery → Electrical system; Rep. Gr.27. Tightening torques

Component		Nm
Guide tube for dipstick to cylinder head		10
Oil pipe to:	Turbocharger	15
	Intake manifold	22
Toothed belt cover to	Cylinder head	10
	Injection pump	10
Heat shield to turbocharger		10