Cylinder Head, Installing

Special tools and workshop equipment required 

• Sealant. Refer to the Parts Information.
• Commercially available blade scraper (blade width minimum 40 mm)

Procedure 

• Do not use any sanding materials (sandpaper, sand stone sanding pads, sanding strips, or abrasive cloths etc.).
• May not be applied on sealing surfaces.
• The dark discoloration does not need to be removed.
• When removing the sealant residue pay attention that no loosened sealant residue gets into the channel to the engine.
• Pay attention to the neighboring work stations cleanliness and that no there is no sanding from above.
• The use of unpermitted sanding materials can cause subsequent damage, such as turbocharger damage, connecting rod bearing, etc.

-- Remove the sealing lip from the cylinder head and cylinder block using only a commercially available blade scraper (blade width minimum 40 mm).

-- Remove any loose residue with a lint-free cloth.

• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Only unpack the new cylinder head gasket immediately before installing.
• To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.
• If a replacement cylinder is installed, only remove the plastic base right before cylinder head is installed to protect open valves.
• Replace bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts, gaskets, seals and O-rings after removal.
• The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.
• When installing a replacement cylinder head, the contact surfaces between the roller rocker lever and cam running surface need to be oiled before the camshaft housing can be installed.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• When replacing the cylinder head or cylinder head gasket, replace all of the coolant and engine oil.

-- Check whether the alignment sleeves -arrows- are inserted in cylinder block. (Shown on the bank 2 cylinder block.)

Courtesy of AUDI OF AMERICA, LLC

-- Check whether the throttle pins -1- are inserted in cylinder block.

-- Clean any oil or grease off the sealing surfaces.

• Be sure to check the expiration date of the sealant.
  Fig 1: Cut Tube Nozzle At Front Marking

  Courtesy of AUDI OF AMERICA, LLC

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2.0 mm).

Cylinder Bank 1 (Right): 

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-- Apply sealant beads -1 and 2- as shown on the clean sealing surfaces of the cylinder block and the lower timing chain cover.

• Sealant bead thickness: 2 mm.

Cylinder Bank 2 (Left): 

Courtesy of AUDI OF AMERICA, LLC

-- Apply sealant beads -1 and 2- as shown on the clean sealing surfaces of the cylinder block and the lower timing chain cover.

• Sealant bead thickness: 2 mm.

-- Install the cylinder head gasket on the alignment bushings in the cylinder block.

• Cylinder head gasket installation position: "oben" (top) marking or part number toward the cylinder head.

-- Position the cylinder head.

-- Install the cylinder bolts all the way in by hand.

-- Tighten the cylinder head bolts.

TIP:

It is not required to retighten the cylinder head bolts after repairs.

Install in reverse order of removal. Note the following:

-- Install the starter generator. Refer to GENERATOR, REMOVING AND INSTALLING .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET or A/C COMPRESSOR, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the turbocharger. Refer to TURBOCHARGER, REMOVING AND INSTALLING .

-- Install the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Change the engine oil. Refer to ENGINE OIL .

-- Change the coolant. Refer to COOLANT, DRAINING AND FILLING .

Tightening Specifications 

• Refer to OVERVIEW - CYLINDER HEAD 
• Refer to Figure
• Refer to Figure
• Refer to OVERVIEW - CAMSHAFT TIMING CHAINS 
• Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS