Part II
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, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery Communication.
After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Owners Manual.
After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar, switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module Communication.
Cylinder head, removing and installing
Note:
^ Replace cylinder head bolts.
^ When performing repairs, 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 max. of 0.3 mm in width, or when no more than first 4 turns of spark plug threads are cracked.
Part II
1 - Gasket
^ Note installed position
^ Replace
2 - 10 Nm
3 - 10 Nm
4 - O-ring
^ For injector
^ Replace
5 - Fuel rail
^ With injectors
^ Vehicles up to 06.03: Tighten union nut for fuel supply line to 22 Nm
^ Vehicles as of 07.03: Loosening and tightening union nut for fuel supply line to fuel rail pipe
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
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
Cylinder head resurfacing limit
- Resurfacing the cylinder head (skimming) is only permitted down to minimum dimension - a -.
^ Minimum dimension: - a - = 139.20 mm
Sealing transition points between double bearing cap and cylinder head (2 points):
- Apply a small quantity of sealant Part No: AMV 174 004 01 to sides of joints - arrows -on upper sealing surface of cylinder head.
Sealing camshaft adjuster/cylinder head transition (4 points)
- Apply a small quantity of sealant Part No: AMV 174 004 01 to sides of joints - arrows -on upper sealing surface of cylinder head.
Loosening and tightening union nut for fuel supply line in vehicles as of 07.03
CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
Loosening
- Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1 - and - 3 - and unscrew union nut - 2 -.
Tightening
- Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.