Cylinder Head, Removing And Installing: Installing

WARNING: This page is about a different car, the 2015 Audi A7 Quattro, 2014 Audi A7 Quattro, 2013 Audi A7, and 2012 Audi A7. However, it is still accessible from the selected car via links, so may be relevant.

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 any 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: Identifying Camshaft Adjuster T40133

Courtesy of AUDI OF AMERICA, LLC

Secure the camshafts in the "TDC" position on both cylinder heads using the Camshaft ClampT40133 -arrows- (25 Nm).
The Camshaft ClampT40133 is correctly positioned when the holes for the cylinder head bolts remain free.

Continued for All

Fig 2: Identifying Crankshaft Holder T40069 In Hole, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

Secure crankshaft -1- in "TDC" position using Crankshaft Locking PinT40069.

-- 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 alignment bushings in 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

For Camshafts without Wrench Clearance

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

Continued 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: four bolts.

NOTE:

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

Install in reverse order of removal. Note the following:

-- 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 DIAGRAMS information.

-- 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, refer to appropriate FLUID CAPACITY information .

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