Cylinder head, removing and installing

WARNING: This page is about a different car, the 2010 Audi A8, 2009 Audi A8, 2008 Audi A8, and 2007 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

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Special tools, testers and auxiliary items required

Torque wrench V.A.G 1331
SW 17 socket V.A.G 1331/6
SW 14 socket, open ring V.A.G 1331/8
Multi-point socket T10070

Removing

NOTE:

The procedure is primarily shown for the left cylinder head in the following illustration.
During installation, all cable ties must be re-installed at the same location.

Drain coolant → Cooling system, draining and filling .

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Remove knock sensor electrical connectors - 1 and 2 - from bracket.
Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Remove left coolant pipe → Left coolant pipe, removing and installing .
Remove right coolant pipe → Right coolant pipe, removing and installing (for right cylinder head).

Remove left secondary air injection combi-valve → Left combination valve for Secondary Air Injection, removing and installing (for left cylinder head).
Remove right secondary air injection combi-valve → Right combination valve for Secondary Air Injection, removing and installing .
Remove rear coolant pipe → Rear coolant line, removing and installing .
Remove torque support bracket → Torque support bracket, removing and installing (for right cylinder head).

Remove cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .
Remove affected oxygen sensor in front of catalytic converter → 24 - MULTIPORT FUEL INJECTION (MFI) .
Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
Remove camshaft timing chains from camshafts → Camshaft timing chains, removing from camshafts .

Remove front muffler: left → Left front muffler, removing and installing , right → Right front muffler, removing and installing .

Left cylinder head:

Remove left front wheel.
Remove front part of left front wheel housing liner → 66 - EXTERIOR EQUIPMENT .

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Remove bolt - arrow - and pull hydraulic oil pressure pipe forward slightly.
Remove nuts - 6 to 1 -.

NOTE:

To improve clarity, the engine is shown removed.
Both lower securing strips remain installed.

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Remove bolt - 2 - at left catalytic converter bracket.

NOTE:

Ignore items - 1 and 3 -.

Remove left exhaust manifold from cylinder head stud bolts and securing strips.
Lay aside left exhaust manifold with catalytic converter in engine compartment.

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Right cylinder head:

Remove bolts - 2 through 5 - and remove torque support.

NOTE:

Ignore - 1 -.

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Remove nuts - 6 to 1 -.

NOTE:

To improve clarity, the removed engine is shown.
Both lower securing strips remain installed.

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Remove bolt - 2 - at right catalytic converter bracket.

NOTE:

Ignore - 1 -.

Remove right exhaust manifold from cylinder head stud bolts and securing strips.
Lay aside right exhaust manifold with catalytic converter in engine compartment.

Continued for both sides:

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Remove bolts - 1 and 2 - and remove affected chain tensioner.

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Disconnect electrical connectors - arrows - at fuel injectors.
Remove high pressure line - 2 - from connector on fuel rail.
Remove high pressure line - 1 - from connector on fuel rail by counterholding at hex head with an open end wrench and loosening union nut.

NOTE:

Do not change bent shape of high pressure lines.

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Remove locking bolt - arrow -.

Fig 1: Cylinder Head Bolts Loosening Sequence

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Remove bolts - arrows -.
Using Socket T10070, remove cylinder head bolts in - 1 to 10 - sequence.
Remove bolts and carefully remove cylinder head.
Lay cylinder head on a soft surface (foam).

Installing

Tightening torques → Cylinder head, assembly overview , Cylinder head tightening sequence , → Camshaft timing chain, assembly overview , → Secondary air injection (AIR) system, assembly overview .

CAUTION: Risk of damaging sealing surfaces.

Carefully remove sealant residue from cylinder head and cylinder block.
Make sure that no long scrapes or scratches result.

Risk of damaging cylinder block.

No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of leaks in cylinder head seal.

Carefully remove all grinding and sanding residue.
Only unpack new cylinder head gasket immediately prior to installation.
To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.

Risk of damaging open valves.

If a replacement cylinder head is installed, only remove plastic base right before cylinder head is installed to protect open valves.

Risk of damaging valves and piston heads after working on valvetrain.

To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.

NOTE:

Replace bolts which have been tightened to torque.
Replace self-locking nuts as well as sealing rings and seals.
If a replacement cylinder head is installed, contact surfaces between bearing elements, roller rocker levers and cam running surfaces must be lubricated before installing cylinder head cover.
Secure all hose connections using hose clamps of series-production status
During installation, all cable ties must be re-installed at the same location.

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Check whether camshafts of both cylinder heads stand in "TDC" position.

Camshaft Clamp T40070 must be installed on both cylinder heads and tightened to 25 Nm.

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Crankshaft holder 3242 must be installed.

Position cylinder head gasket.

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

Install cylinder head.

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Tighten cylinder head bolts → Cylinder head tightening sequence

NOTE:

Bolts must not be tightened after repairs.

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Tighten locking screw - arrow -.

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Check whether camshaft timing chain tensioner guide rail is secured with Locking Pin T40071.

NOTE:

If the tensioning element was removed from the chain tensioner, note installation position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.
Disregard - arrow -.

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Clean chain tensioner oil screen - 2 -.
Place a new gasket - 3 - onto rear of chain tensioner - 1 -.
Set chain tensioner in place and install camshaft timing chain, as shown in illustration.

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Tighten bolts - 1 and 2 -.

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

Install exhaust manifold: Left → Left exhaust manifold with catalytic converter, removing and installing , right → Right exhaust manifold with catalytic converter, removing and installing .
Install torque support and torque support bracket → Assembly mount, overview .
Install front muffler: left → Left front muffler, removing and installing , right → Right front muffler, removing and installing .
Install camshaft timing chains Installing .

Install left and right timing chain covers → Installing .
Install rear coolant pipe → Rear coolant line, removing and installing .
Install combination valve for Secondary Air Injection (AIR) system: Left → Left combination valve for Secondary Air Injection, removing and installing , right → Right combination valve for Secondary Air Injection, removing and installing .
Install left coolant pipe → Left coolant pipe, removing and installing .

Install right coolant pipe → Right coolant pipe, removing and installing .
Install cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .
Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Install headlamps → 94 - LIGHTS, SWITCHES - EXTERIOR .

Install front bumper cover → 63 - BUMPERS .
Check headlight adjustment 404.

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To tighten SW 14 union nut at fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 14, open ring V.A.G 1331/8 → 24 - MULTIPORT FUEL INJECTION (MFI) .

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To tighten SW 17 union nut at fuel rail, use Torque Wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6 → 24 - MULTIPORT FUEL INJECTION (MFI) .
Align exhaust system free of tension → Exhaust system, installing free of tension .
Change engine oil 404.
Change coolant → Cooling system, draining and filling .