Cylinder Heads: Installing

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, and 2010 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

Tightening specifications:

CAUTION:

The sealing surfaces could be damaged.

Carefully remove sealant residue from the 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 the valve train.

To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 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.

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

Secure the camshafts in the Top Dead Center (TDC) position on both cylinder heads using the T40133 -arrows- (25 Nm).

Fig 1: Identifying Camshaft Adjuster T40133
Courtesy of AUDI OF AMERICA, LLC
The T40133 is correctly positioned when the holes for the cylinder head bolts remain free.

Secure crankshaft -1- in TDC position using T40069.

Fig 2: Identifying Crankshaft Holder T40069 In Hole, Removal/Installation
Courtesy of AUDI OF AMERICA, LLC

-- 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 "top" or the part number must be legible.
Pay close attention to the alignment bushings in the cylinder block -arrows-.

-- Set cylinder head in place.

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

Fig 4: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

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

Fig 5: Identifying Bolts At Rear Of Cylinder Head

Courtesy of AUDI OF AMERICA, LLC

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 paying attention to the following:

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

-- Install front coolant pipe. Refer to FRONT COOLANT PIPE .

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

-- Position the camshaft timing chain on the camshafts. Refer to CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

-- Remove the lower section of the intake manifold. Refer to Removal and Installation .

-- Installing the ribbed belt:

-- Install the upper coolant pipe. Refer to UPPER COOLANT PIPE .

-- Change the engine oil. Refer to the the appropriate Service Information .

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