Cylinder Heads, Removing And Installing: Installing

WARNING: This page is about a different variant/trim than selected.

Tightening specifications. Refer to OVERVIEW - CYLINDER HEAD .

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.

No oil or coolant must be in the cylinder head bolt blind holes 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 two full revolutions.

NOTE:

Replace any bolts that were tightened with an additional turn.

Replace self-locking nuts, sealing rings, seals and O-rings.

For the correct seal and cylinder head bolts.

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

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Change the coolant and engine oil whenever replacing the cylinder head or cylinder head seal.

Applies to Cylinder Head with Camshafts Installed

Fig 1: Camshaft Adjuster T40133

Courtesy of AUDI OF AMERICA, LLC

Secure the camshafts in the Top Dead Center (TDC) position on both cylinder heads using the Camshaft ClampT40133 -arrows- (25 Nm).
The Camshaft ClampT40133 is correctly positioned when the holes for the cylinder head bolts remain free.

Continued for All

Fig 2: Crankshaft Locking Pin T40069

Courtesy of AUDI OF AMERICA, LLC

Secure crankshaft -1- in "TDC" position using Crankshaft Locking PinT40069.

-- Install the new seals on the coolant pipe.

Fig 3: Identifying Alignment Bushings In Cylinder Block -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Set cylinder head gasket in place.

Installed position: the marking "oben" (top) or the part number must be legible.
Pay close attention to alignment bushings in cylinder block -arrows-.

-- Set cylinder head in place.

-- Tighten the cylinder head bolts. Refer to Figure.

Fig 4: Cylinder Head Bolt Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

Applies to Cylinder Head with Camshafts Removed

-- Install the camshafts. Refer to CAMSHAFTS, REMOVING AND INSTALLING .

Continued for All

Fig 5: Identifying Bolts At Rear Of Cylinder Head

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -arrows- for the lower timing chain cover Figure.

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

NOTE:

There is no requirement to tighten the cylinder head bolts after repairs.

Install in reverse order of removal. Note the following:

-- Install oil dipstick guide tube. Refer to Figure.

-- Install front coolant pipe. Refer to FRONT COOLANT PIPE, REMOVING AND INSTALLING .

-- Electrical connections and wiring routing. Refer to the appropriate Wiring Diagram.

-- Install the power steering pump. Refer to POWER STEERING PUMP, REMOVING AND INSTALLING .

-- Install the camshaft timing chains. Refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .

-- Install the catalytic converter. Refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING , RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION WITH FUEL RAIL, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the upper coolant pipe. Refer to UPPER COOLANT PIPE, REMOVING AND INSTALLING .

-- Change engine oil. Refer to Maintenance, Diagnosis .

-- Replace the coolant. Refer to COOLANT, DRAINING AND FILLING .