Audi Workshop Service and Repair Manuals

Installing cylinder head Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „Cylinder head - exploded view“   Caution Avoid damage to sealing surfaces. t  Carefully remove sealant residue from cylinder head and cylinder block. t  Ensure that no long scores or scratches are made on the surfaces. Avoid damage to cylinder block. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. Risk of leaks at cylinder head gasket. 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  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket. Avoid damage to open valves. When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. Avoid damage to valves and piston crowns after working on valve gear. Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts as well as seals, gaskets and O-rings. t  Cylinder heads must not be reworked on TDI engines. t  When installing an exchange cylinder head, the contact surfaces between roller rocker fingers and cams must be oiled before installing the cylinder head cover. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and the coolant in the entire cooling system.

–  Before installing cylinder head, set crankshaft and camshafts to „TDC“: l  Locking pin -3242- must be screwed in with crankshaft at „TDC“ position -1-.

l  The camshafts on both cylinder heads must be locked with adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft.

–  Note cylinder head gasket identification: 1 -  Holes 2 -  Part number   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. t  The gaskets for the left and right cylinder heads have different shapes and cannot be interchanged. –  Clean surfaces; they must be free of oil and grease.   Note

t  Note the use-by date of the sealant. t  Cut off nozzle of tube at front marking (nozzle Ø approx. 5 mm). t  After applying sealant, components must be installed and secured within 15 minutes. Cylinder head (left-side):

–  Apply sealant beads -1- and -2- onto clean sealing surface of cylinder block and timing chain cover (bottom) as illustrated.

–  Apply sealant according to dimensions given. l  a = 7 mm l  b = 7 mm l  c = 7 mm –  Place cylinder head gasket in position.

–  Apply sealant beads -1- and -2- onto cylinder head gasket as shown in illustration. Cylinder head (right-side):

–  Apply sealant beads -1- and -2- onto clean sealing surface of cylinder block and timing chain cover (bottom) as illustrated.

–  Apply sealant according to dimensions given. l  a = 7 mm l  b = 7 mm l  c = 7 mm –  Place cylinder head gasket in position.

–  Apply sealant beads -1- and -2- onto cylinder head gasket as shown in illustration.

Continuation for both sides: l  Pay attention to dowel sleeves -arrows- in cylinder block. l  Installation position of cylinder head gasket: the word „oben“ (top) or the part number should face towards the cylinder head. –  Fit cylinder head.

–  Tighten cylinder head bolts → Fig..   Note Cylinder head bolts do not have to be torqued down again later after repair work. Cylinder head (left-side): –  Engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB: install toothed belt tensioning roller and toothed belt for high-pressure pump → Rep. gr.23. –  Engine code CAPA: install toothed belt for high-pressure pump → Rep. gr.23. –  Install connecting pipe for exhaust gas recirculation → Chapter. –  Install dipstick guide tube → Chapter. Cylinder head (right-side): –  Install coolant pipe (top right) → Chapter. –  Install intermediate pipe (right-side) → Chapter. Continuation for both sides: –  Install high-pressure pipes → Rep. gr.23. –  Install cylinder head cover: left-side → Chapter; right-side → Chapter. –  Install intake manifold (top section) → Rep. gr.23. –  Install camshaft timing chains: engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB → Anchor, engine code CAPA → Anchor. –  Change engine oil → Booklet811, → Booklet812 or → Booklet818. –  Fill cooling system with fresh coolant → Anchor. –  Check fuel system for leaks → Chapter.