Cylinder Head, Installing Audi A4 B6

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. In case of repairs, carefully remove sealant residue from cylinder head and cylinder block. Avoid introducing any scratches or scoring. Thoroughly remove all sanding and grinding residue. Pocket holes in cylinder block for cylinder head bolts must be free of oil and coolant. Do not remove new cylinder head gasket from package until immediately before installing. Handle gasket with extra care. Damage in silicon layer and recessed area lead to leakage. Install cylinder head gasket onto guide sleeves. Marking "oben" (top) or part number must face toward cylinder head. Secure all hose connections using hose clamps appropriate for the model type: see Parts catalog

Installation is reverse of removal, noting the following

Scheme 255

Scheme 256

Scheme 257

Scheme 258

1. Before installing cylinder head, set crankshaft and camshafts to TDC cylinder 3
2. T40030 camshaft adjuster gauge must be inserted at both cylinder heads.
3. ... and T40026 locking pin must be threaded in.
4. Install cylinder head gasket. Observe centering pins (arrows) in cylinder block. Pay attention to installed position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.
5. Install cylinder head.
6. Insert new cylinder head bolts and hand-tighten.
7. Tighten cylinder head bolts in sequence, in two stages.
8. Tighten using torque wrench: 1. Stage: 40 Nm
9. Tighten using a solid wrench: 2. Stage: 180° (1/2 turn) further NOTE: Two additional turns of 90° are permissible. It is not necessary to re-tighten the cylinder head bolts.
10. Install toothed belt (adjust timing). See «INSTALLING (ADJUSTING VALVE TIMING)»(ref-197058-S24630182892005101100000) . NOTE: After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.
11. Install left front exhaust pipe with catalytic converter. See «EXHAUST SYSTEM, SERVICING»(ref-197059-S06297763462005101100000) .
12. Install right front exhaust pipe with catalytic converter See «EXHAUST SYSTEM, SERVICING»(ref-197059-S06297763462005101100000) .
13. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (FRONT WHEEL DRIVE VEHICLES)»(ref-197059-S22984853552005101100000) or «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(ref-197059-S41932014202005101100000) .
14. Install centering pin for intake manifold.
15. Install intake manifold. See «INSTALLING»(ref-197058-S32461615212005101100000) .

See Caution for connecting Telematics battery . See EMERGENCY BATTERY, SWITCHING OFF/ON .

1. Observe safety precautions after connecting the battery. See «BATTERY DISCONNECT PRECAUTIONS»(ref-164692-S22212771322004091500000) .
2. Replace coolant. See «COOLANT, DRAINING AND REFILLING»(ref-229837-S04500895302006042100000) .
3. Fill up power steering fluid and bleed steering system: See «POWER STEERING»(ref-197184-S18295748992005101300000) .