Cylinder head, installing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace cylinder head bolts.
Replace self-locking nuts and bolts during assembly work.
Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.
In case of repairs, carefully remove sealant residue from cylinder head and cylinder block. Avoid introducing any scratches or scoring.
Thoroughly remove all sanding and grinding residue.
Pocket holes in cylinder block for cylinder head bolts must be free of oil and coolant.
Do not remove new cylinder head gasket from package until immediately before installing.
Handle gasket with extra care. Damage in silicon layer and recessed area lead to leakage.
Install cylinder head gasket onto guide sleeves. Marking "open" (top) or part number must face toward cylinder head.
Secure all hose connections using hose clamps appropriate for the model type:

Installation is reverse of removal, noting the following:

Before installing cylinder head, set crankshaft and camshafts to TDC cylinder 3:

Fig 1: Inserting T40030 Camshaft Adjuster Gauge At Left Cylinder Head In Same Manner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

T40030 camshaft adjuster gauge must be inserted at both cylinder heads...

Fig 2: Threading T40026 Locking Pin Into Hole Of Removed Sealing Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

.. and T40026 locking pin must be threaded in.

Fig 3: Installing Cylinder Head Gasket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install cylinder head gasket.

Observe centering pins (arrows) in cylinder block.
Pay attention to installed position of cylinder head gasket, marking "open" (top) or part number must face toward cylinder head.

Install cylinder head.
Insert new cylinder head bolts and hand-tighten.

Fig 4: Tightening LH Cylinder Head Bolts In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten cylinder head bolts in sequence, in two stages.

Tighten using torque wrench:

1. Stage: 40 Nm

Tighten using a solid wrench:

2. Stage: 180° (1/2 turn) further

NOTE:

Two additional turns of 90° are permissible.
It is not necessary to re-tighten the cylinder head bolts.

Install toothed belt (adjust timing). Refer to Installing (adjusting valve timing) .

NOTE: After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Install left front exhaust pipe with catalytic converter. Refer to Installing for vehicles with manual transmission and Installing for vehicles with automatic transmission 01V.
Install right front exhaust pipe with catalytic converter. Refer to Installing for vehicles with manual transmission and Installing for vehicles with automatic transmission 01V.
Install exhaust system free of stress. Refer to Exhaust system, aligning free of stress (vehicles with front wheel drive) and Exhaust system, aligning free of stress (vehicles with all wheel drive) .
Install centering pin for intake manifold.

Install intake manifold. Refer to Installing .

See Caution for connecting Telematics battery. Refer to Cylinder head, removing and installing

Observe safety precautions after connecting the battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Replace coolant. Refer to Filling .
Fill up power steering fluid and bleed steering system:

Refer to 48 - STEERING

Tightening torques

Component		Nm
Rear coolant pipe to cylinder head		10
Combination valve to cylinder head		10
Rear toothed belt guard to cylinder head or cylinder block		10 1)
Bracket for idler roller to cylinder head		10 1)
Front coolant pipe	M6	10
To cylinder head	M8	23
Power steering pressure line to hydraulic pump		47
Power steering pressure line to cylinder head		10
Power steering pressure line to rear coolant pipe		20

1) Replace bolts.