Cylinder Head, Removing and Installing: Overview

Cylinder head, removing and installing

CAUTION: Before beginning repairs on the electrical system:
^ Obtain the anti-theft radio security code.
^ Switch the ignition off.
^ Disconnect the battery Ground (GND) strap.
^ On vehicles equipped with Audi Telematics by OnStar A, switch-off the emergency (backup) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery, Refer to Repair Information.
^ After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Owner's Manual.
^ After reconnecting vehicle battery on vehicles equipped with Audi Telematics by Onstage, switch-on the emergency (backup) battery for the Telematic/Telephone Control Module, Refer to Repair Information.

Notes:
^ Replace cylinder head bolts.
^ When performing replace seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
^ Charge air hose connections and hoses must be free from oil and grease before installing.
^ When installing a replacement cylinder head with camshafts installed, contact surfaces between valve lifter and cam running surface must be oiled after installation of cylinder head.
^ The plastic protectors installed to protect open valves must only be removed immediately before installing cylinder head.
^ When replacing cylinder head or cylinder head gasket, the coolant must be completely replaced.
^ Cylinder heads which have cracks between valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided cracks do not exceed a maximum of 0.3 mm in width, or when no more than first 4 turns of spark plug threads are cracked.





Part I
1. Cylinder head gasket
^ Replace - Removing cylinder head, Refer to Cylinder Head, Service and Repair
^ Installation position: Part No toward cylinder head
^ After replacing, fill with fresh coolant
2. Cylinder head
^ Removing, Refer to Cylinder head, removing
^ Checking for distortion, Refer to Fig 1
^ Resurfacing limit, Refer to Fig 2
^ Installing, Refer to Cylinder head, installing
^ After replacing, fill with fresh coolant
3. Oil deflector
^ Note installation position
4. Cylinder head bolt
^ Replace
^ Note sequence when loosening, Refer to Cylinder head, removing
^ Note sequence when tightening, Cylinder head, installing
5. Cylinder head cover
^ Removing and installing, Refer to Valve Cover, Service and Repair
6. Ignition coil
7. Cap
8. Gasket
^ Replace if damaged or leaking
9. 10 Nm
^ Tighten inner nuts first
^ Tighten outer nuts in diagonal sequence
10. Cylinder head cover gaskets
^ Replace if damaged or leaking
^ Before installing gaskets apply "AMV 174 004 01" at sealing points and, Refer to Cylinder Head, Service and Repair
11. Gasket
^ Replace
12. Secondary air combination valve
^ With screw connection
13. 10 Nm
14. Coolant flange
^ With coolant temperature sensor
15. 10 Nm
16. O-ring
^ Replace






Part II
1. Gasket
^ Note installation position
^ Replace
2. 10 Nm
3. 10 Nm
4. O-ring
^ For injector
^ Replace
5. Fuel rail
^ With injectors
6. Coolant line (top)
7. 10 Nm
8. 10 Nm
9. O-ring
^ For top coolant line
^ Replace
10. 10 Nm
11. Intake manifold
12. 20 Nm
13. Support
^ For intake manifold





Fig. 1 Checking cylinder head for distortion
^ Check cylinder head for distortion at several points using knife-edge straightedge and feeler gauge.
^ Max. permissible distortion: 0.1 mm





Fig. 2 Cylinder head resurfacing limit
^ Resurfacing the cylinder head (skimming) is only permitted down to minimum dimension a.
^ Minimum dimension: a = 139.20 mm





Fig. 3 Sealing transition points between double bearing cap and cylinder head
^ Apply a small quantity of sealant "AMV 174 004 01" to sides of joints -arrows- on upper sealing surface of cylinder head.





Fig. 4 Sealing camshaft adjuster/cylinder head transition
^ Apply a small quantity of sealant "AMV 174 004 01" to sides of joints -arrows- on upper sealing surface of cylinder head.