Cylinder Head, Removing And Installing

WARNING: This page is about a different car, the 2010 Audi Q7, 2009 Audi Q7, 2008 Audi Q7, and 2007 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Lifting Tackle3033
Shop CraneVAS6100
Sealant

Removal

Proceed as follows:

The engine is installed.

NOTE:

When Installation, bring all cable ties back to same positions.

WARNING:

There is a risk of injury because the fuel is under very high pressure.

Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure.

-- Reduce the fuel pressure in the high pressure area, refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

-- Drain the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Remove the intake manifold, refer to INTAKE MANIFOLD .

-- Remove the cylinder head cover, refer to CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Remove timing chain upper cover upper section, refer to TIMING CHAIN GUARD UPPER SECTION, REMOVING AND INSTALLING .

-- Remove camshaft timing chain from camshafts, refer to CAMSHAFT TIMING CHAIN, REMOVAL FROM CAMSHAFTS .

-- Remove ribbed belt tensioner, refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING .

Fig 1: Identifying Electrical Harness Connector -1-

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WARNING:

Risk of injury from fuel.

To reduce residual pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Remove fuel supply line -2-.

NOTE:

Ignore -Item 1-.

-- Disconnect electrical connector -2- for Low Fuel Pressure Sensor -G410- at top of high pressure pump.

Fig 2: Locating Fuel Pressure Sensor -G247- And Low Fuel Pressure Sensor -G410-

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NOTE:

Ignore -Item 1-.

Depending on the version, the Low Fuel Pressure Sensor -G410- sits on the plenum chamber bulkhead.

-- Disconnect electrical connector -arrow- for Fuel Metering Valve -N290- at bottom of high pressure pump.

Fig 3: Locating Fuel Metering Valve -N290-

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-- Disconnect electrical connectors -arrows- on fuel injectors.

Fig 4: Identifying Electrical Connectors -Arrows- On Fuel Injectors

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NOTE:

Ignore -Items 1 through 7-.

-- Free up B+ wire to starter on left rear engine lifting eye.

-- Remove bolts -arrows- on coolant connecting pieces.

Fig 5: Identifying Bolts -Arrows- On Coolant Connecting Pieces

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NOTE:

Ignore -items 1, 2 and 3-.

-- Remove bolts -arrows- and remove heat shield.

Fig 6: Identifying Bolts -Arrows- And Heat Shield

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-- Remove bolt -arrow- and remove ground wire.

Fig 7: Identifying Bolt -Arrow- And Ground (GND) Wire

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-- Roll up heat insulation sleeve -1- and remove coolant hose from cylinder head.

-- Remove bolts -2- on main primary converter brackets.

Fig 8: Identifying Primary Catalytic Converter Bracket Bolts

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NOTE:

Ignore -Item 1-.

-- Remove nuts -arrows- and remove pre-catalytic converters from threaded pins.

Fig 9: Identifying Exhaust Pipe With Catalytic Converter To Exhaust Manifold Nuts -Arrows-

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-- Remove the bolts -2-.

Fig 10: Identifying Sealing Flange Bolts

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NOTE:

Ignore -Item 1-.

-- Remove control housing -arrows- carefully remove from camshaft compression rings.

Fig 11: Locating Control Housing-To-Cylinder Head Bolts

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-- Lay aside camshaft timing chain.

-- Loosen and remove the cylinder head bolts in the sequence -1 to 20-.

Fig 12: Cylinder Head Bolt Removal Sequence

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-- Engage Lifting Tackle3033 as follows:

Fig 13: Attaching Lifting Tackle 3033

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Belt pulley side: item "3".
Transmission side: item "11".

-- Carefully raise cylinder head.

CAUTION:

Risk of contaminating cylinder wall and piston.

Place clean cloths in cylinder.

Installation

Tightening specifications, refer to Figure, EXHAUST MANIFOLD OVERVIEW .

CAUTION:

The sealing surfaces could be damaged.

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

Risk of damaging cylinder block.

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Risk of cylinder head seal leaking.

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 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 valve train.

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

NOTE:

Replace the bolts which are being tightened with an additional turn.

Replace sealing rings, seals and self-locking nuts.

Note different sealant for cylinder head sealing surfaces and bolts.

If a replacement cylinder is installed, contact surfaces between bearing elements, roller rocker levers and cam running surfaces must be lubricated before Installation cylinder head cover.

Secure all hose connections using hose clamps appropriate for the model type.

-- Position camshafts at "TDC" before cylinder head is installed.

Fig 14: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

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Camshaft BarT10068 A must be situated in grooves in both camshafts.

-- Check again if crankshaft is at "TDC" marking.

Fig 15: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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The markings on the vibration damper and sealing flange must align -arrow-.

-- Check whether fitting sleeves are inserted in cylinder block -arrows-.

Fig 16: Identifying Fitting Sleeves Inserted In Cylinder Block -Arrows-

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-- Apply a sealant bead -arrows- to clean sealing surfaces on cylinder block joint and timing chain cover.

Fig 17: Identifying Sealant Location For Cylinder Block/Sealing Flange

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Sealant bead thickness: 2.0 mm

CAUTION:

Risk of plugging oil pump strainer with excess sealant.

Do not apply sealant bead thicker than indicated.

-- Immediately apply cylinder head seal.

Installation position: it must be possible to read the part number.

-- Always put some sealant in both of the 3 mm holes that lie on the sealant bead.

-- Set cylinder head in place.

-- Apply sealant in area -1- of cylinder head bolts.

Fig 18: Identifying Sealant Location For Cylinder Head Bolt

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-- Insert long bolts in center bores in cylinder head.

Fig 19: Cylinder Head Tightening Sequence

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-- Tighten the cylinder head bolts, refer to Figure.

NOTE:

Do not tighten cylinder head bolts after repairs.

-- Install the camshaft timing chain and control housing, refer to CAMSHAFT TIMING CHAIN, REMOVAL FROM CAMSHAFTS , refer to CAMSHAFT TIMING CHAINS OVERVIEW /

-- Install the cylinder head cover, refer to CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install pre-catalytic converters, refer to CATALYTIC CONVERTERS, REMOVING AND INSTALLING .

-- Install the intake manifold, refer to INTAKE MANIFOLD .

-- Change engine oil, refer to Maintenance Booklet #406.

-- Replace coolant, refer to COOLANT, DRAINING AND FILLING .