Cylinder head, installing: Notes

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, and 2003 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace cylinder head bolts.
When performing repairs, replace seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
Secure all hose connections with standard hose clamps
When performing repair work, carefully remove any remains of gasket material from cylinder head and cylinder block. Make sure that no long scores or scratches are made on surfaces.
Carefully remove any remaining emery and abrasive material.
Remove new cylinder head gasket from packaging just before installation.
Handle gasket extremely carefully. Damaging the silicone layer or indented area will lead to leaks.
No oil or coolant must be allowed to remain in blind holes for cylinder head bolts in cylinder block.

Fig 1: Identifying Marking On Camshaft Gear Aligned With Marking On Cylinder Head Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before positioning cylinder head, set crankshaft and camshaft to TDC No. 1 cylinder.

Fig 2: Locating Bolts On Turbocharger Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolts - 1 - and - 2 - on turbocharger bracket approx. 2 turns to avoid setting up stresses when installing cylinder head.

Fig 3: Identifying Cylinder Block Centering Pins

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place cylinder head gasket in position.

Note position of centering pins in cylinder block - arrows -.
Check installed position of cylinder head gasket: Part No. should be visible from intake side.

Position cylinder head.
Insert cylinder head bolts and hand-tighten.

Fig 4: Cylinder Head Bolt Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten cylinder head bolts in two stages in sequence shown as follows:
Tighten using torque wrench:

Step 1: 40 Nm

Tighten with normal fixed wrench:

Step 2: 180 ° (1/2 turn) further (2 x 90 ° turns permissible)

NOTE:

It is not necessary to re-tighten cylinder head bolts after repairs have been performed.

Bolt turbocharger with new gasket to exhaust manifold and bolt bracket to cylinder block → Turbocharger, removing and installing - overview .
Install cylinder head cover
Install toothed belt (adjust valve timing) → Toothed drive belt, removing, installing and tensioning .
Install ribbed belt and ribbed belt tensioner → Ribbed belt, removing and installing .

Install intake manifold.
Replace coolant → Cooling system, draining and filling .

See Caution for connecting Telematics battery → Cylinder head, removing and installing

After connecting battery, enter radio anti-theft code. Radio operating instructions.
Use electric window lifters to completely close door windows.
Then actuate all window lifter switches again for at least 1 second in "close" position to activate automatic one-touch function.
Set clock to correct time.

Perform adaptation of throttle valve control module: → 24 - MULTIPORT FUEL INJECTION (MFI)