Cylinder Head, Removing And Installing: Installing

WARNING: This page is about a different car, the 2009 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

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.

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

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 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.

-- Before installing the cylinder head, set the crankshaft and camshafts to "TDC" and install the Camshaft Clamp T40133 on both cylinder heads and tighten to 25 Nm -arrows-.

Fig 1: Before Installing Cylinder Head, Set Crankshaft And Camshafts To "TDC"

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The Camshaft Clamp T40133 is correctly positioned when the holes for the cylinder head bolts remain free.

Crankshaft Locking Pin T40069 must be screwed into the crankshaft.

Fig 2: Crankshaft Locking Pin T40069
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-- Set cylinder head gasket in place.

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

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Pay close attention to centering pins -arrows- in cylinder block.
Cylinder head gasket installation position: "oben" (top) marking or part number toward cylinder head.

-- Set the cylinder head in place .

Left cylinder head:

Fig 4: Identifying Unloaded Camshaft Slider & Bolts (Left Cylinder Head)

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-- Insert the bolts -1 through 7- while sliding the unloaded camshaft slider -A- accordingly.

-- Tighten the bolts in 3 steps following the sequence -1 to 7-. Refer to OVERVIEW - CYLINDER HEAD .

Right cylinder head:

Fig 5: Identifying Unloaded Camshaft Slider & Bolts (Right Cylinder Head)

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-- Insert the bolts -8 through 14- while sliding the unloaded camshaft sliders -D- and -E- accordingly.

-- Tighten the bolts in 3 steps following the sequence -8 to 14-. Refer to OVERVIEW - CYLINDER HEAD .

Continuation for both cylinder heads:

Fig 6: Identifying TDC With Special Tool Adapter T40058

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-- Position the camshaft timing chain on the camshafts. Refer to INSTALLING .

-- Remove the Camshaft Clamp T40133 and the Crankshaft Locking Pin T40069.

-- Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the Crankshaft Socket T40058.

The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine.

Fig 7: Identifying Exhaust Camshaft Openings Alignment
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Left cylinder head:

Fig 8: Slide Unloaded Camshaft Sliders As Far As The Stop In Direction Of -Arrow-

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-- Slide the unloaded camshaft sliders -B- and -C- as far as the stop in the direction of the -arrow-.

Right cylinder head:

Fig 9: Slide Unloaded Camshaft Slide As Far As Stop In Direction

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-- Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Continuation for both cylinder heads:

Fig 10: Identifying TDC With Special Tool Adapter T40058

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-- Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the Crankshaft Socket T40058.

The threaded holes -arrows- in the camshafts must face upward.

Fig 11: Identifying Camshaft Threaded Hole Alignment
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Left cylinder head:

Fig 12: Identifying Bolt

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-- Insert the bolt -15- and tighten it in 3 steps. Refer to OVERVIEW - CYLINDER HEAD .

Right cylinder head:

Fig 13: Identifying Bolt -16-

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-- Insert the bolt -16- and tighten it in 3 steps. Refer to OVERVIEW - CYLINDER HEAD .

Continuation for both cylinder heads:

Fig 14: Identifying TDC With Special Tool Adapter T40058

Courtesy of AUDI OF AMERICA, LLC

-- Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the Crankshaft Socket T40058.

The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine.

Fig 15: Identifying Exhaust Camshaft Openings Alignment
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Left cylinder head:

Fig 16: Slide Unloaded Camshaft Slider As Far As Stop In Direction Of -Arrow-

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-- Slide the unloaded camshaft slider -B- as far as the stop in the direction of the -arrow-.

Right cylinder head:

Fig 17: Slide Unloaded Camshaft Sliders As Far As The Stop In Direction Of -Arrow-

Courtesy of AUDI OF AMERICA, LLC

-- Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Continuation for both cylinder heads:

Fig 18: Identifying Bolts At Rear Of Cylinder Head

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-- Tighten the bolts -arrows-.

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

NOTE:

Do not tighten cylinder head bolts after repairs.

Install in reverse order of removal. Note the following:

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

-- Position the camshaft timing chain on the camshafts. Refer to INSTALLING .

-- Install the cylinder head cover. For the left side. Refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING and for the right side refer to RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

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

-- Install the power steering pump. Refer to OVERVIEW - POWER STEERING PUMP .

-- Install the left catalytic converter: for vehicles with manual transmissions. Refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING . For vehicles with the multitronic 0AW or automatic transmission 0B6, refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the right catalytic converter: for vehicles with manual transmissions/manual transmission 0AW, refer to RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING . For vehicles with the automatic transmission 0B6 or automatic transmission 0B6, refer to RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Install the plenum chamber bulkhead. Refer to OVERVIEW - BULKHEAD .

-- Install the high pressure line, fuel supply line and the lower section of the intake manifold. Refer to OVERVIEW - INTAKE MANIFOLD LOWER SECTION WITH FUEL RAIL .

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

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

-- Change the engine oil. Refer to the appropriate "FLUID CAPACITY TABLES" information.

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