Cylinder head, installing Audi A8 D3 facelift

Cylinder head, installing

Special tools, testers and auxiliary items required

1. Polydrive Bit and Drive Socket T10070

1. Crankshaft Holder 3242

Installing

Note. Replace cylinder head bolts. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. After installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters, cam followers 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. Reworking the cylinder heads is not permissible. 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. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks. 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 . After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

1. Before positioning cylinder head, set crankshaft and camshafts on DTC cylinder 5

1. The large holes - arrows - on securing plates at camshaft gears must align on inside.

1. Crankshaft holder 3242 must be installed.

Scheme 211

1. Set cylinder head gasket in place.

1. Pay close attention to alignment bushings in cylinder block - arrows -.
2. Pay attention to installation position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.

1. Set cylinder head in place.
2. Insert new cylinder head bolts and tighten by hand.

Scheme 212

1. Tighten cylinder head in sequence indicated, in four stages as follows
2. Tighten with torque wrench

1. 1. Step: 30 Nm
2. 2. Step: 60 Nm

1. Tighten using a solid wrench

1. 3. Step: 90° ( 1 / 4 turn) further
2. 4. Step: 90° ( 1 / 4 turn) further

Note. There is no requirement to retighten the cylinder head bolts after repairs.

Further installation is in reverse order of removal, note the following

1. Install cylinder head cover on left --> «Left cylinder head cover, removing and installing»(ref-289202-S14564763332008062700000) or right --> «Right cylinder head cover, removing and installing»(ref-289202-S03900222242008062700000) .
2. Install right combination valve for secondary air injection system --> «Secondary Air Injection (AIR) (right combination valve), removing and installing»(ref-289202-S17063550702008062700000) .
3. Install front exhaust pipe.
4. Install intake manifold --> «24 MULTIPORT FUEL INJECTION (MFI)»(ref-289207-S35560862182008062700000) .

1. Install toothed belt (adjust timing) --> «Toothed belt, removing and installing»(ref-289202-S15249254682008062700000) .

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.

1. Install engine --> «Installing»(ref-289202-S23647061342008062700000) .
2. Replace coolant.
3. Install torque support --> «Torque support (with torque support valve N382), assembly overview»(ref-289202-S41597847662008062700000) .

Torque specifications

1. Insert 1) bolts using locking compound; locking compound