Cylinder Head, Installing: Procedure

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Tightening Specifications

Refer to OVERVIEW - CYLINDER HEAD .
Refer to Figure.

CAUTION:

There Is A Risk Of Damaging The Sealing Surfaces.

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

Risk Of Damaging The 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 Gasket.

Carefully remove the sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
Carefully remove all grinding and sanding residue.
Only unpack the new cylinder head gasket immediately before installing.
To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.

There Is A 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 The Valves And Piston Crowns After Working On Valvetrain.

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

NOTE:

Replace The Bolts That Were Tightened With An Additional Turn.

Replace the self-locking nuts, gaskets, seals and O-rings.

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

Secure all hose connections with hose clamps that match the ones used in series production.

It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.

-- Check whether the camshafts on both cylinder heads stand in "TDC" position.

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

Courtesy of AUDI OF AMERICA, LLC

Camshaft Clamp:T40070 mounted on both cylinder heads and tightened to 25 Nm -arrows-.

Crankshaft Holder:3242 installed

Fig 2: Identifying Crankshaft Holder 3242 Into Hole, Removal/Installation
Courtesy of AUDI OF AMERICA, LLC

NOTE:

The Following Illustrations Show The Left Cylinder Head Instead.

-- Position The Cylinder Head Gasket.

Pay close attention to alignment bushings in cylinder block -arrows-.

Fig 3: Identifying Alignment Bushings In Cylinder Block
Courtesy of AUDI OF AMERICA, LLC
Cylinder head gasket installation position: "oben" (top) marking or part number toward the cylinder head.

-- Position The Cylinder Head.

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

Fig 4: Cylinder Head Bolts Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

NOTE:

It Is Not Required To Retighten The Cylinder Head Bolts After Repairs.

-- Tighten the sealing plug -arrow-.

Fig 5: Identifying Locking Bolt

Courtesy of AUDI OF AMERICA, LLC

-- Check if the guide rail for the camshaft timing chain tensioner is secured with the :T40071 .

Fig 6: Pressing Left/Right Camshaft Timing Chain Guide Rail Inward And Securing Chain Tensioner With Locking Pin T40071

Courtesy of AUDI OF AMERICA, LLC

NOTE:

If The Tensioner Was Removed From The Chain Tensioner, Then Pay Close Attention To The Installed Position: The Hole In The Bottom Of The Housing Faces The Chain Tensioner And The Piston Faces The Tensioning Rail.

Ignore the -arrow-.

-- Clean the chain tensioner oil screen -2-.

Fig 7: Identifying Chain Tensioner Oil Screen, Gasket & Chain Tensioner

Courtesy of AUDI OF AMERICA, LLC

-- Position a new seal -3- on the rear of the chain tensioner -1-.

-- Insert the chain tensioner and position the camshaft timing chain as shown in the illustration.

Fig 8: Identifying Bolts For Left Chain Tensioner And Left Camshaft Timing Chain

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -1 and 2-.

The rest of the installation is performed in reverse order of removal. Note The Following:

-- Install the cylinder head cover: left. Refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING ; right. Refer to RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install the high pressure lines and the intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Position the camshaft timing chains on the camshafts. Refer to Installing .

-- Install the timing chain covers. Refer to LEFT TIMING CHAIN COVER, REMOVING AND INSTALLING for the left and RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING for the right.

-- Change the engine oil. Refer to appropriate service information.

-- Change the coolant. Refer to FILLING .