Attention. Before removing or installing the cylinder head, align the alignment marks with the piston of cylinder No. 1 to the top dead center position (TDC).
Rotate the crankshaft so that the alignment mark is one quarter of a turn away from the TDC mark. This will prevent the valves from falling onto the piston. After installing the cylinder head, install the crankshaft in the desired position.
Note. The cylinder head should be removed after each engine cooldown.
Elements of the cylinder head of a 6-cylinder engine
1 cylinder head
2 Exhaust valve
3 intake valve
4 Camshaft
5 Hydropusher
6 Rusks
7 Top cymbal
8 Spring
9 Oil cap
1 Top cover gasket
11 Cylinder head gasket
12 Camshaft gear
13 Tension roller
14 Toothed belt
15 Bypass roller
16 Timing belt cover
17 Bypass roller
Elements of the cylinder head of a 5-cylinder engine
A Engine with two valves per cylinder
B Engine with 4 valves per cylinder
1 cylinder head
2 Cylinder head gasket
3 Gasket set (during engine repair)
4 Toothed belt cover
5 toothed belt
6 Camshaft gear (anterior)
7 Valve guide
8 Top cover gasket
9 Toothed belt cover (rear)
1Camshaft
11 Camshaft gear (rear)
12 Toothed belt (rear)
13 Hydraulic pusher
14 Upper spring plate
15 Oil cap
16 Exhaust valve
17 Inlet valve
18 Bottom plate and spring retainer
19 Valve springs
2Valve cotters
21 Toothed belt
22 Camshaft gear
23 Chain
24 Gasket
25 Camshafts
26 Gasket
27 Gasket set (during engine repair)
28 Cylinder head
4 and 5 cylinder engines
Disconnect wire from "minus" AB.
Drain coolant.
Disconnect air duct from throttle body on all vehicles except Quattro models. On Quattro models, disconnect the hose that goes from the air duct to the turbocharger. Disconnect the throttle cable from the throttle valve assembly.
Remove the air duct from the injector cooling fan on Quattro models.
Clean and remove fuel injectors and all other fuel lines.
Attention: Put caps on fuel injectors and cold start.
Tag and disconnect all vacuum and positive crankcase breather hoses.
Remove the hose that goes from the intake manifold to the turbocharger.
Tag and disconnect all electrical wires to the cylinder head.
Remove intake manifold.
Disconnect all radiator and heater hoses that are attached to the cylinder head. Pin them to the side.
Tag and disconnect all high voltage wires from spark plugs.
Remove distributor. To facilitate installation, scratch a mark on the distributor housing and cylinder head.
Separate the exhaust manifold from the exhaust pipe.
Disconnect the EGR valve (RVG) and an oxygen sensor from the exhaust manifold.
Detach the heat shield.
Disconnect all oil lines (2 pieces) from the turbocharger.
Remove exhaust manifold.
Note: When removing the exhaust manifold on Quattro models, the manifold, turbocharger and exhaust chamber must be removed as one unit.
Remove the air hose cover from the back of the generator.
Tag and disconnect all wires coming from the rear of the generator and remove the generator from the engine.
Tag and disconnect the hoses from the power steering pump.
Remove the power steering pump and V-belt.
Remove the toothed belt cover and the belt itself.
Remove valve cover.
Loosen cylinder head bolts in reverse order to tightening.
Remove bolts and remove cylinder head.
Cylinder head bolt tightening sequence - 4-cylinder engines
5 cylinder engines
Installation
Thoroughly clean the mating surfaces of the block and cylinder head and install a new gasket without sealant. Make sure the words "TOR" And "OBEN" directed upward. Install the head on the block and install the #8 and #10 bolts first. Their bores are smaller and they will properly center the gasket and head on the cylinder block.
Install the remaining bolts. Tighten them sequentially in three stages as follows:
- Stage No. 1: torque 39 Nm.
- Stage No. 2: torque 58 Nm.
- Stage 3: Tighten half a turn (180°).
Install the valve cover.
Install toothed belt and toothed belt cover.
Install the power steering pump and drive belt.
Install alternator and all wires.
Install the exhaust manifold.
Connect the two oil lines to the turbocharger.
Install heat shield.
Connect the RVG valve and oxygen sensor to the exhaust manifold.
Connect exhaust system.
Install the distributor and spark plug wires.
Install intake manifold.
Install radiator and heater hoses.
Install fuel injectors. Connect air line.
Connect throttle cable
Connect the wire to the minus AB.
Fill the cooling system and bleed air. Check all fluid levels.
Test the car in motion
6 cylinder engine
The following procedure is for the left cylinder head when the engine is installed in the vehicle. For the right head, this procedure must be modified accordingly.
Disconnect the wire from the minus AB. Drain coolant. Relieve fuel pressure.
Remove V-belt.
Remove toothed belt. The vibration damper must remain installed.
Remove the exhaust pipe from the manifold.
Remove air hose between airflow sensor and intake manifold.
Remove and tag all spark plug wires and injector plugs.
Remove the crankcase ventilation pipes on the right and left cylinder head covers.
Remove the fuel supply and return pipes. Remove muffler.
Remove the left fuel line cover.
Disconnect the throttle cable.
Tag and remove all vacuum hoses from vacuum pump and intake manifold.
Disconnect plug at idle speed control valve and throttle valve potentiometer.
Disconnect the vacuum hose from the vacuum control unit.
Disconnect plugs from oil pressure switch and oil pressure warning light switch.
Disconnect plug from Hall sender.
Remove the RVG hose from the intake manifold.
Remove intake manifold assembly.
Remove the coolant pipe from the rear of the cylinder head.
Remove oxygen sensor.
Remove the heat shield on the exhaust manifold.
Remove the cylinder head cover.
Remove toothed belt and rear belt guard. Remove the hydraulic hose from the tank to the pump.
Loosen the bolts in the reverse order of tightening and remove the cylinder head from the engine.
The sequence of tightening the bolts of the cylinder head of a 6-cylinder engine
Installation
Clean all mating surfaces. Check the cylinder head for deformation. Take measurements at several points. The maximum allowable deformation is 0.1 mm.
Install the cylinder head gasket. The letters on the gasket should face up.
Install the cylinder head using the alignment pins on the cylinder block.
Insert the cylinder head bolts by hand.
Tighten the head bolts in the sequence shown in the figure in two stages:
- Stage #1: 6Nm.
- Stage 2: Tighten half a turn (180°).
Install rear toothed roller guard.
Install the cylinder head cover.
Install the oxygen sensor. Install the heat shield to the exhaust manifold.
Install intake manifold.
Install the RVG valve to the intake manifold.
Connect the plugs to the Hall sensor, to the oil pressure sensor and the oil pressure warning light switch.
Connect the plugs to the idle speed control valve and throttle valve potentiometer.
Install all vacuum hoses to vacuum pump and intake manifold.
Connect the throttle cable.
Connect the fuel supply and return pipes. Install muffler.
Install the crankcase ventilation pipes to the cylinder head cover.
Install all spark plug wires and connect injector plugs.
Install the exhaust manifold.
Install toothed belt and V-belt.
Fill the cooling system and bleed air.
Check all fluid levels. Let the engine run at normal operating temperature and check for leaks.
Test the car in motion.
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