08 Oct

Head Removal DIY #2 Audi 1.8t

Posted by: admin  /  Category: Audi, Engine

Another Head Removal DIY to use as a supplement to

Quote, originally posted by CYLINDER HEAD REMOVAL & INSTALLATION »
CAUTION
Cylinder head removal should not be attempted unless the engine is cold.
1.8L Engine
1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
* Front bumper
3. Place the hood lock carrier into the service position.
4. Turn the ignition switch to the OFF position.
5. Remove or disconnect the following:
* Negative battery cable
* Accessory drive belt
* Cooling fan
6. Drain the engine coolant.
7. Remove or disconnect the following:
* Intake manifold
* Accessory drive belts
* Wastegate bypass regulator valve
* Evaporative Emissions (EVAP) canister purge regulator valve
* Power outage stage
* Mass Air Flow (MAF) sensor
* Air cleaner housing
* Engine Temperature Control (ETC) and the temperature II sensor harness connector
* All connections from the cylinder head
* Crankcase breather line
* Oil supply line at the cylinder head
* Exhaust manifold heat shield
* Turbocharger from the exhaust manifold
* Coolant hose to the heat exchanger at the rear of the cylinder head
* Upper timing belt cover
8. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at TDC.
9. Using Torx® wrench T45, loosen the timing belt tensioner.
10. Push down on the tensioner and remove the belt from the camshaft gear.
11. Remove or disconnect the following:
* Torx® bolt and swing the tensioner assembly bracket forward
* Valve cover

* Cylinder head bolts, in sequence, as shown
* Cylinder head
12. Clean the gasket mating surfaces.
13. Clean and dry out the cylinder head bolt holes.To install:

NOTE: Always replace the cylinder head bolts, self-locking nuts, bolts, gaskets and O-rings.

NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
14. Before installing the cylinder head, set the crankshaft and camshaft to TDC for the No. 1 cylinder.
15. Loosen the turbocharger support bracket to reduce the likelihood of any tension while installing the cylinder head.
16. Install or connect the following:
* Head gasket with the part number visible from the intake side
* Cylinder head
* New cylinder head bolts, tighten by hand
17. Tighten the new cylinder head bolts in sequence in 2 steps:
Step 1: 44 ft. lbs. (60 Nm)
Step 2: additional 1⁄2 (180 degree) turn
NOTE: It is not necessary to retighten the cylinder head bolts.

18. Install or connect the following:
* Turbocharger to the exhaust manifold using new gaskets and the bolts coated with Hot Bolt Paste G 052 112 A3. Tighten the bolts to 26 ft. lbs. (35 Nm).
* Turbo support bracket. Tighten the bolts to 33 ft. lbs. (40 Nm).
* Valve cover
* Timing belt
* Accessory drive belts
* Exhaust manifold heat shield
* Oil supply lines to the cylinder head. Tighten the retaining straps to 15 ft. lbs. (20 Nm).
* Crankcase breather
* Any other items removed during disassembly
* Coolant temperature sensors
* Air cleaner housing
19. Fill the engine with coolant and bleed, if necessary.
20. Connect the negative battery cable.
21. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function.
22. Check the oil level before starting the engine and top off, as necessary.
23. Set the clock to the correct time.

NOTE: DTCs are stored when harness connectors are detached.

24. Clear the fault codes, as necessary.
25. Install or connect the following:
* Hood lock carrier assembly
* Front bumper
26. Adjust the headlights.

http://forums.vwvortex.com/zerothread?id=3425946

Quote, originally posted by CYLINDER HEAD REMOVAL & INSTALLATION »
CAUTION
Cylinder head removal should not be attempted unless the engine is cold.
1.8L Engine
1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
* Front bumper
3. Place the hood lock carrier into the service position.
4. Turn the ignition switch to the OFF position.
5. Remove or disconnect the following:
* Negative battery cable
* Accessory drive belt
* Cooling fan
6. Drain the engine coolant.
7. Remove or disconnect the following:
* Intake manifold
* Accessory drive belts
* Wastegate bypass regulator valve
* Evaporative Emissions (EVAP) canister purge regulator valve
* Power outage stage
* Mass Air Flow (MAF) sensor
* Air cleaner housing
* Engine Temperature Control (ETC) and the temperature II sensor harness connector
* All connections from the cylinder head
* Crankcase breather line
* Oil supply line at the cylinder head
* Exhaust manifold heat shield
* Turbocharger from the exhaust manifold
* Coolant hose to the heat exchanger at the rear of the cylinder head
* Upper timing belt cover
8. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at TDC.
9. Using Torx® wrench T45, loosen the timing belt tensioner.
10. Push down on the tensioner and remove the belt from the camshaft gear.
11. Remove or disconnect the following:
* Torx® bolt and swing the tensioner assembly bracket forward
* Valve cover

* Cylinder head bolts, in sequence, as shown
* Cylinder head
12. Clean the gasket mating surfaces.
13. Clean and dry out the cylinder head bolt holes.To install:

NOTE: Always replace the cylinder head bolts, self-locking nuts, bolts, gaskets and O-rings.

NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
14. Before installing the cylinder head, set the crankshaft and camshaft to TDC for the No. 1 cylinder.
15. Loosen the turbocharger support bracket to reduce the likelihood of any tension while installing the cylinder head.
16. Install or connect the following:
* Head gasket with the part number visible from the intake side
* Cylinder head
* New cylinder head bolts, tighten by hand
17. Tighten the new cylinder head bolts in sequence in 2 steps:
Step 1: 44 ft. lbs. (60 Nm)
Step 2: additional 1⁄2 (180 degree) turn
NOTE: It is not necessary to retighten the cylinder head bolts.

18. Install or connect the following:
* Turbocharger to the exhaust manifold using new gaskets and the bolts coated with Hot Bolt Paste G 052 112 A3. Tighten the bolts to 26 ft. lbs. (35 Nm).
* Turbo support bracket. Tighten the bolts to 33 ft. lbs. (40 Nm).
* Valve cover
* Timing belt
* Accessory drive belts
* Exhaust manifold heat shield
* Oil supply lines to the cylinder head. Tighten the retaining straps to 15 ft. lbs. (20 Nm).
* Crankcase breather
* Any other items removed during disassembly
* Coolant temperature sensors
* Air cleaner housing
19. Fill the engine with coolant and bleed, if necessary.
20. Connect the negative battery cable.
21. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function.
22. Check the oil level before starting the engine and top off, as necessary.
23. Set the clock to the correct time.

NOTE: DTCs are stored when harness connectors are detached.

24. Clear the fault codes, as necessary.
25. Install or connect the following:
* Hood lock carrier assembly
* Front bumper
26. Adjust the headlights.

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