Cylinder Head, Removing And Installing, Engine Without Wrench Clearance: Installing

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 two 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, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the camshafts.

The hose supports, air guide pipes and hoses must be free of oil and grease before installing.

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

To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

-- Set cylinder head gasket in place.

Fig 1: Identifying Centering Pins

Courtesy of AUDI OF AMERICA, LLC

Pay attention to centering pins in cylinder block -arrows-.
Cylinder head gasket installed position: the part number must be readable from the intake side.

WARNING:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- If the crankshaft was turned in the meanwhile: bring the piston for cylinder 1 to TDC and then turn the crankshaft back just a little.

-- Set cylinder head in place.

-- Insert cylinder head bolts and tighten by hand.

-- Cylinder head tightening sequence. Refer to Figure.

NOTE:

It is not necessary to retighten the cylinder head bolts after repairs.

-- Rotate the vibration damper using the Counterhold - Vibration Damper T10355 into the "TDC" position -arrow-.

Fig 2: Identifying Vibration Damper "TDC" Position With Special Tool T10355

Courtesy of AUDI OF AMERICA, LLC

The notch on the vibration damper must line up with the arrow marking on the lower timing chain cover.

Further installation is performed in the reverse order of removal, thereby observing the following:

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

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Change the engine oil. Refer to ENGINE OIL, EXTRACTING AND REPLACING OIL FILTER

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

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

-- Install the front exhaust pipe/front muffler. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

WARNING:

Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.