Cylinder head, removing and installing: Installing

NOTE:

Do not allow any oil or coolant to remain in the blind holes for the cylinder head bolts in the cylinder block.
REPLACE cylinder head bolts.
Connecting vacuum hoses. See VACUUM DIAGRAM - COMPLETE .

When installing a new cylinder head:

Screw in centering pin for intake manifold.

The cylinder head supplied as a replacement part can be used on both sides (left or right). But a sealing cap (core plug) must be installed in the front end of the cylinder head in each case.

Coat outside circumference of sealing cap (core plug) with sealant AMV 188 001 02.
Using drift VW 295, knock in sealing cap (core plug) until outside rim is flush with end of the chamfer in cylinder head.

Fig 1: Locating Core Plug In Cylinder Head
Courtesy of AUDI OF AMERICA, INC.
Before installing cylinder head in position, turn crankshaft and camshafts to TDC of No. 3 cylinder.
Install cylinder head gasket on dowel sleeves. Marking "oben" (top) or part number must face towards cylinder head.
Install cylinder head, insert cylinder head bolts and tighten finger-tight.
Tighten NEW cylinder head bolts in two stages in sequence (Fig 2), as follows:
- Stage 1 = 60 Nm.
- Stage 2 = turn a further 1/2 turn (180°) with a rigid wrench (turning 2 x 90° is also permissible).

Fig 2: Identifying Left Cylinder Head Bolts Tightening Sequence

Courtesy of AUDI OF AMERICA, INC.

It is not necessary to torque down cylinder head bolts again after repairs have been completed.

Seal end points of joints between bearing caps and cylinder head.
Before installing cylinder head cover and gasket, carefully apply a small quantity of sealant D 454 300 A2 at four end points of sealing surfaces on cylinder head -arrows-, using a small screwdriver.

Fig 3: Locating Seal End Points Of Joints Between Bearing Caps And Cylinder Head

Courtesy of AUDI OF AMERICA, INC.

NOTE:

Do not allow any oil or coolant to remain in the blind holes for the cylinder head bolts in the cylinder block.
Install NEW cylinder head bolts.
Connecting vacuum hoses. See VACUUM DIAGRAM - COMPLETE .

When installing a new cylinder head:

Screw in centering pin for intake manifold.

The cylinder head supplied as a replacement part can be used on both sides (left or right). But a sealing cap (core plug) must be installed in the front end of the cylinder head in each case.

Coat outside circumference of sealing cap (core plug) sealant AMV 188 001 02.
Using drift VW 295, knock in sealing cap (core plug) until outside rim is flush with end of chamfer in cylinder head.

Fig 1: Locating Core Plug In Cylinder Head
Courtesy of AUDI OF AMERICA, INC.
Before installing cylinder head in position, turn crankshaft and camshafts to TDC of No. 3 cylinder.
Install cylinder head gasket on dowel sleeves. Marking "oben" (top) or part number must face towards cylinder head.
Install cylinder head, insert cylinder head bolts and tighten finger-tight.
Tighten NEW cylinder head bolts in two stages in sequence (Fig 2), as follows:
- Stage 1 = 60 Nm.
- Stage 2 = turn a further 1/2 turn (180°) with a box wrench (turning 2 x 90° is also permissible).

Fig 2: Identifying Right Cylinder Head Bolt Tightening Sequence

Courtesy of AUDI OF AMERICA, INC.

It is not necessary to torque down cylinder head bolts again after repairs have been completed.

Seal end points of joints between bearing caps and cylinder head.
Before installing cylinder head cover and gasket, carefully apply a small quantity of sealant D 454 300 A2 at four end points of sealing surfaces on cylinder head -arrows-, using a small screwdriver.

Fig 3: Identifying Seal End Points Of Joints Between Bearing Caps And Cylinder Head

Courtesy of AUDI OF AMERICA, INC.