Table of contents: On the engine model "WH" ↓ On the engines of models "WC", "KP",… ↓ On engines of all models ↓
Clean the crushed parts and visually inspect them to determine their technical condition. Clean the surfaces of the connectors using appropriate detergents. Do not use abrasive materials or objects that can leave scratches for cleaning. Replace all gaskets with new ones during assembly.
Install the cylinder head gasket with the surface with the inscriptions facing the cylinder head plane.
Install dowel pins 2083 into the holes for mounting bolts 9 and 10 (see photo) of the cylinder head.
Cylinder head dowel pin and dowel pin remover
Install new cylinder head bolts with new washers
Tighten the cylinder head mounting bolts in three stages, observing the order (see photo) of tightening the bolts and tightening torques 1st stage 4.0 kgf·m; 2nd reception 6.0 kgf·m; 1st step: turn 180°.
Cylinder head bolt tightening sequence (arabic numerals 1 to 12) and nuts of studs of fastening of caps of bearings of the camshaft (roman numerals, first I through IV, then V through VIII)
Install the camshaft drive belt and adjust the tension.
On the engines of models "WH", "WC", "KP" check the valve clearances and adjust them if necessary.
Install the exhaust manifold and attach the muffler intake manifold flange using a new gasket.
Install the intake manifold.
Depending on the configuration, install the power steering pump, put on the drive belt and adjust its tension.
Connect the outlet hose to the radiator, connect the interior heating system hoses to the cylinder head, and connect the inlet hose to the radiator.
Install the throttle cable in place.
Screw the spark plugs into the cylinder head sockets.
Install the crankcase ventilation hose.
On the engine model "WH"
Connect the connectors of the electrical components installed on the cylinder head and the connectors of the intake manifold heater.
Connect the vacuum hoses to the carburetor.
Install a damping valve and a fuel drain bypass valve into the tank.
Connect the fuel lines.
Install the air filter.
On the engines of models "WC", "KP", "KU", "RT", "NF"
Install the injection nozzles, having previously moistened the nozzle cuffs with gasoline, and tighten the nozzle mounting flange.
Reinstall the disconnected injection system pipes, replacing the gaskets on the fittings.
Install the air duct connecting the air flow meter to the throttle body.
On engines of all models
Further installation of the cylinder head is carried out in the reverse order of removal. After installing the cylinder head, do the following:
- fill the cooling system with coolant;
- check the oil level in the engine crankcase;
- connect the wire to the battery.
- adjust the ignition timing. engine idle speed. On engines of models "WH", "WC", "KP" and "RT" check the working clearances in the valve mechanism on a warm engine if the cylinder head was disassembled.
Text provided by the online resource AudiManual