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.

Note:
^ Replace cylinder head bolts.
^ Replace self-locking nuts and bolts during assembly work.
^ Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.
^ After installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters and cam lubricating surfaces after installing cylinder head.
^ Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head.
^ When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.
^ If a cylinder head is replaced, a cap must be driven in on the front part of the respective head, Refer to Fig 3,.
^ Cylinder heads with cracks between valve seats or between valve seat and spark plug thread can still be used without loss of service life if the cracks are minute (maximum 0.3 mm width) or only the first four threads of a spark plug thread are cracked.





Part I
1. Intake manifold
- Removing and installing, Refer to Intake Manifold, Service and Repair
2. Resonator
3. 10 Nm
4. O-Rings
- Always replace
5. Fuel return line
6. Fuel supply line
- Union nut, tighten to 25 Nm
7. Socket
8. 10 Nm
9. Holding plate
- for solenoid valves
10. Fuel distributor
11. Air duct
12. 10 Nm
13. O-ring
- Always replace
14. 10 Nm
15. 10 Nm
- tighten diagonally in sequence
16. Gasket for intake manifold Always replace





Part II
1. Cylinder head gasket
- replacing - removing cylinder head, Refer to Left Cylinder Head, Removing onward
- Installation position: Part number to cylinder head
- After replacing, replace coolant
2. Cylinder head
- Removing left cylinder head, Refer to Left Cylinder Head, Removing
- Removing right cylinder head, Refer to Right Cylinder Head, Removing
- Check for warpage, Refer to Fig 1
- Refacing dimension, Refer to Fig 2
- Sealing cap (core plug) in cylinder head installing, Refer to Fig 3
- Installing, Refer to Cylinder Head, Installing
- After replacing, replace coolant
3. Lifting eye
4. 23 Nm
5. Cylinder head bolt
- Always replace
- Follow order of removal, Refer to Left Cylinder Head, Removing
- Follow tightening order, Refer to Cylinder Head, Installing
6. Centering pin
- for intake manifold
7. Special bolt - 10 Nm
- Follow order of tightening, Refer to Valve Cover, Service and Repair.
8. Gasket
- Replace if damaged or leaking
9. Cap
10. O-ring
- Always replace
11. Hose of crankcase housing ventilation
12. Ignition coil
13. Cylinder head cover
- Left cylinder head cover, removing and installing, Refer to Valve Cover, Service and Repair.
- Right cylinder head cover, removing and installing, Refer to Valve Cover, Service and Repair.
14. Cylinder head cover gasket
- Replace if damaged or leaking
15. 10 Nm
16. Rear coolant pipe
17. Combination valve for secondary air injection (AIR)
18. 10 Nm
19. Gasket
- Always replace
20. O-ring
- Always replace





Fig. 1 Check cylinder head for warpage
^ Using straightedge and feeler gauge, check cylinder head for warpage at multiple points.
^ Maximum permissible warpage: 0.1 mm





Fig. 2 Cylinder head refacing dimension
^ Refacing cylinder head can only be done to minimum dimension -a-.
^ Minimum dimension: a = 139.25 mm

Fig. 3 Sealing cap (core plug) in cylinder head, driving in





Special Tools and Equipment
^ VW295 needle bearing drift
Cylinder heads which are supplied as replacement parts can be used on left or right and a cap must be installed on the respective front side.
^ Coat lip of sealing cap with sealant.
^ Sealant
Refer to Parts Supplier
^ Drive sealing cap flush into cylinder block using VW295 needle bearing drift.