Cylinder Head, Installing, All Engines: Notes

WARNING: This page is about a different car, the 2016 Audi A6 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview and parts information prior to starting procedure.

Mandatory Replacement Parts

Bolt - Cylinder Head Cover to Cylinder Head
Cylinder Head Gasket - Cylinder Head to Cylinder Block
Bolt - Cylinder Head to Cylinder Block
O-rings - Coolant Lines to Cylinder Head
O-ring - Hose to Cylinder Head Cover
O-ring - Fuel Return Hose to Injector
O-ring/Copper Ring - Injector to Cylinder Head Cover

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.

No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of leaks in cylinder head seal.

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.

It is not permitted to re-work the cylinder heads on TDI engines

If a replacement cylinder is installed, contact surfaces between the roller rocker lever and the cam lubricating surface must be lubricated before installing cylinder head cover.

Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Parts information.

When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.

-- Note the marking on the cylinder head gasket:

Courtesy of AUDI OF AMERICA, LLC

Part Number
Holes

NOTE:

If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.

If parts of the crank drive were replaced, then the new cylinder head gasket must be determined by measuring the piston projection in "TDC". Refer to PISTON PROJECTION, MEASURING AT TOP DEAD CENTER (TDC) .

The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

-- Set cylinder head gasket in place.

Courtesy of AUDI OF AMERICA, LLC

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

-- Set cylinder head in place.

-- Tighten the cylinder head bolts. Refer to OVERVIEW - CYLINDER HEAD .

NOTE:

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

Install in reverse order of removal. Note the following:

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

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

-- Install the high pressure lines. Refer to HIGH PRESSURE LINES, REMOVING AND INSTALLING .