Cylinder head, removing and installing: Installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace cylinder head bolts.
During assembly, replace self-locking nuts and bolts.
Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
Carefully remove all grinding and sanding residue.
There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Checking cylinder head for distortion Checking cylinder head for distortion
Only unpack new cylinder head gasket immediately prior to installation.
Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage.
Install cylinder head gasket onto guide sleeves. Marking "oben" (top) or part number must face toward cylinder head.
After installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller cam followers and cam lubricating surfaces after installing cylinder head.
Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head.
When replacing cylinder head or cylinder head seal, coolant and engine oil must be changed.
Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.
After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Fig 1: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads And Locating Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing cylinder head, set crankshaft and camshafts to TDC setting, mounting camshaft locating tool T40070 on both cylinder heads and tightening to 20 Nm.

The camshaft locating tool T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

Fig 2: Installing Crankshaft Holder T40069 Into Hole

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Crankshaft holder T40069 must be installed into crankshaft - 1 -.

Position cylinder head gasket.

Fig 3: Paying Close Attention To Centering Pins In Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pay close attention to centering pins - arrows - in cylinder block.
Pay attention to installation position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.

Install cylinder head.

Fig 4: Tightening Cylinder Head Bolts In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert new cylinder head bolts and tighten by hand.
Tighten cylinder head in sequence indicated, in 3 stages as follows:
Using torque wrench, tighten to 40 Nm.
With Torx key, 90 ° ( ¹ /₄ turn) additional turn.

With Torx key, 90 ° ( ¹ /₄ turn) additional turn.

NOTE:

There is no requirement to retighten the cylinder head bolts.

Fig 5: Removing/Installing Bolts At Rear Of Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolts - arrows - to 9 Nm.

Left cylinder head: 3 bolts.
Right cylinder head: 4 bolts.

Further installation is in reverse order of removal, note the following:

Install camshaft timing chains Installing .
Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
Install cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .
Install front exhaust pipe with catalytic converter: Left, Vehicles with manual transmission → Left front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing , Vehicles with automatic transmission → Left front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing ; Right, Vehicles with manual transmission → Right front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing , Vehicles with automatic transmission → Right front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing .

Align exhaust system free of tension → Exhaust system, installing free of tension .
Install right drive axle → 40 - FRONT SUSPENSION .
Install oil filter housing → Oil filter housing, removing and installing .
Install power steering pump → 48 - STEERING .

Install front coolant pipe → Front coolant line, removing and installing .
Install ribbed belt Installing .
Install intake manifold lower-part with high and low-pressure lines → 24 - FUEL INJECTION SYSTEM .
Install intake manifold upper-part → 24 - FUEL INJECTION SYSTEM .

Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Change engine oil →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.
Replace coolant → Cooling system, draining and filling .

Fill power-steering system oil and bleed steering system → 48 - STEERING .

Torque specifications

Component	Nm
Oil dip stick guide tube to cylinder head	9
Fuel hose to fuel line	22