Cylinder Head, Removing and Installing
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.
^ After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.
^ 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.
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 go 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 (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
^ Loosening and tightening union nut in vehicles as of 07.03 go to Fig. 4
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
Part II
1. Cylinder head gasket
^ Installed position: Part number to cylinder head
^ After replacing, replace coolant
2. Cylinder head
^ Check for warpage go to Fig. 1
^ Refacing dimension go to Fig. 2
^ Sealing cap (core plug) in cylinder head, installing go to Fig. 3
^ After replacing, replace coolant
3. Lifting eye
4. 23 Nm
5. Cylinder head bolt
^ Always replace
6. Centering pin
^ For intake manifold
7. Special bolt, 10 Nm
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
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
- Drive sealing cap flush into cylinder block using VW295 needle bearing drift.
Fig. 4 Loosening and tightening union nut for fuel supply line in vehicles as of 07.03
WARNING: Fuel system is under pressure! Before opening system, place rags around the connection. 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.