Cylinder Head, Removing And Installing: Installing

• Do not use any sanding materials (sandpaper, sand stone sanding pads, sanding strips, or abrasive cloths etc.).

  Courtesy of AUDI OF AMERICA, LLC

• May not be applied on sealing surfaces (see illustration).
• 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 surfaces using a corresponding brush from the Cleaning Set for Sealing Surfaces :VAS 294 019  and a commercially available chemical sealant remover.

• Brush:VAS 294 019/1  for gray cast-iron surfaces
• Brush:VAS 294 019/2  for aluminum surfaces
• Brush:VAS 294 019/3  for painted surfaces

-- 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.
• Carefully remove all grinding and sanding residue.
• 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.
• 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.
• When replacing the cylinder head or cylinder head gasket, replace all of the coolant and engine oil.

-- 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).

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: 1.9 to 2.8 mm

-- Position the cylinder head gasket.

Fig 2: Identifying Centering Pins In Cylinder Block

Courtesy of AUDI OF AMERICA, LLC

• Installation position: it must be possible to read the part number.
• Pay close attention to alignment sleeves in cylinder block -arrows-.

-- Apply sealant beads -1 and 2- in the depicted area at the inside of the cylinder head cover.

Courtesy of AUDI OF AMERICA, LLC

• Sealant bead thickness: 1.9 to 2.8 mm
• Install the cylinder head within five minutes after applying the sealant.

-- Position the cylinder head and tighten the bolts.

-- Remove the escaping sealant.

TIP:

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

Install in reverse order of removal. Note the following:

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

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

-- Connect the fuel supply line. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION, REMOVING AND INSTALLING .

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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

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

After removing or replacing the cylinder head/cylinder head gasket the adaptation values for the chain length must be adapted again.

-- Connect the Vehicle Diagnostic Tester.

-- Select Diagnostic  operating mode and Start diagnostics  .

-- Select the Select individual test  tab and select the following tree structure consecutively:

• Drive  (display depends on the model)
• Select the engine code and engine  (display depends on the model)
• 0001 - OBD-Capable Systems  or Diagnostic-Capable System 
• 0001 - Engine Electronics 
• 0001 - Engine electronics, functions 
• 0001 - Adaptation diagnostic chain length