Cylinder Head, Removing And Installing: Installing

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Tightening specifications:

Refer to OVERVIEW - CYLINDER HEAD .
Refer to Figure.
Refer to Figure

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 that were 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 .

The coolant and engine oil must be changed whenever replacing the cylinder head or cylinder head seal.

For Camshafts with Wrench Clearance

Fig 1: Camshaft Clamp T40133 (Left Cylinder Head Shown)

Courtesy of AUDI OF AMERICA, LLC

Secure the camshafts in the "TDC" position on both cylinder heads using the Camshaft Clamp T40133 -arrows- (25 Nm).
The Camshaft Clamp T40133 is correctly positioned when the holes for the cylinder head bolts remain free.

Continuation for All

Fig 2: Crankshaft Locking Pin T40069

Courtesy of AUDI OF AMERICA, LLC

Crankshaft -1- secured in "TDC" using Crankshaft Locking Pin T40069.

-- Install new seals and O-rings for the front 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 Bolts

Courtesy of AUDI OF AMERICA, LLC

For Camshafts without Wrench Clearance

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

Continuation 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, refer to Figure.

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

NOTE:

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

Installation is performed in reverse order of removal, while noting the following:

-- Install oil dipstick guide tube, refer to Figure.

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

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

-- Electrical connections and wiring routing, refer to appropriate SYSTEM WIRING DIAGRAM.

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

-- Connect the coolant hose to the coupling, refer to Fig 6.

Fig 6: Connecting Coolant Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

-- Install the oil filter housing, refer to OIL FILTER HOUSING, REMOVING AND INSTALLING .

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

-- Change the engine oil.

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