Part I

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 (R), switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery.
^ 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 OnStar (R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

Cylinder head, removing and installing

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.
^ 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 (max. 0.3 mm width) or only the first four threads of a spark plug thread are cracked.





Part I
1 -Intake manifold

2 - Resonator

3 - 10 Nm

4 - O-Rings
^ Always replace

5 - Fuel return line
^ Only in vehicles up to 06.03

6 - Fuel supply line
^ For vehicles up to 06.03, tighten union nut to 22 Nm

WARNING! Fuel system is under pressure! Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.

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