Removing and installing cylinder head, AHK — AUDI

AEC AHK
10 Nm
Fuel manifold
20 Nm
20 Nm
Intake manifold
10 Nm
Cylinder head bolts
Replace
Tightening method =>Page
15-54

Cylinder head
Inspecting for distortion =>Page
15-61
Reworking dimension
=>Page
15-52

10 Nm
10 Nm
55 Nm
Use holding tool 3036

Cylinder head gasket
Identification: Lettering must face upwards.

Removing

with engine in situ

Notes:

Ask customer for radio anti-theft code.
Battery is located on right of luggage compartment beneath trim.
With the ignition switched off disconnect the battery earth strap.

Renew all cut and loosened cable ties. Refit cable ties in the same position when installing the engine.
Renew all gaskets and seals.

Remove noise insulation.
Remove vent grille in bumper on left.
Detach exhaust pipes from manifold.

Drain off coolant; to do so, attach hose to drain cock.
Removing and installing toothed belt => Page
15-27
.

Detach pipe of servo unit.
Pull off vacuum pipe at cruise control unit.
Detach accelerator cable.
Detach coolant pipe to heating (supply and return) at bleeder valves.

Detach connector for knock sensor on left and right at fuel manifold; cut open the four tie bands.
Pull off connectors at injectors.
Unscrew fuel manifold and set aside carefully together with injectors.

Unscrew and lift out intake manifold.
Unscrew top manifold/front pipe connection.
Pull off connectors at ignition coils.
Unscrew coolant pipe at rear between the two cylinder heads on left and right and pull out.

Remove cylinder head covers.

Only when removing left cylinder head:

Unscrew and pull out guide tube for dipstick.

Unfasten cylinder head bolts. This is to be done in the reverse order of tightening => Page
15-54
.
Lift off cylinder head.

Checking cylinder head for distortion

Measure at several points with bevelled rule.
Distortion: no more than 0.1 mm

Rework cylinder head

Reworking of cylinder head (face grinding) is only permitted to minimum dimension a = 139.25 mm.

Installing:

Clean sealing surfaces.
Cylinder head gasket: Mark "top" must face cylinder head.
Fit cylinder head, paying attention to centring pins in cylinder block.
Always replace cylinder head bolts.
Insert cylinder head bolts and tighten by hand.

Cylinder head tightening method

Sequence-see illustration

Tightening torque (engine cold)
1. Stage · 40 Nm
2. Stage · 60 Nm
3. Stage · 1/2 turn (180o)

Continue tightening in one operation using fixed wrench. 2 x 90o further turning is permitted.

Notes:

Cylinder head bolts do not have to be retightened when performing standard service or following repairs.
Before installing intake manifold, first attach front breather hose beneath intake manifold to engine.
Installing cylinder head covers => Page
15-64
.