Question 1

How should the cylinder head be removed and refitted with the engine cold for 1.6 litre SOHC petrol engines on Audi A3?

Accepted Answer

Cylinder head has to be pulled off when the engine is cold and new cylinder head bolts and a gasket should be used when refitting. The first thing is to turn off the ignition and remove the key and then the engine top cover and drain the cooling system. Take out the upper inlet manifold with the clean cloths inserted in the lower manifold port to avoid dust entering the machine. Unscrew the distribution case of the coolant of the left side of the cylinder head, reassembling the O-ring without removing hoses. Unscrew the clip and unplug the breather hose at the rear outlet of the cylinder head and unplug all the wiring, and record their locations. Unbolt the exhaust front part including the catalytic converter and lift it off to the side, and remove the auxiliary drivebelt and timing belt. Disassemble the timed belt inner cover, the camshaft sprocket, and (in models with secondary air injection) disconnect and remove the pipes and pump used. Disassemble the hose and the charcoal canister solenoid valve, remove spark plug HT leads, camshaft position sensor wiring, and the right-angled bracket complete with auxiliary drivebelt tensioner. Hold the engine with a hoist or trolley jack, the pertinent bracket should be attached to the cylinder block. When supporting the engine, remove the camshaft cover and ensure that all the wiring, pipes and hoses are unconnected. Tighten and loosen progressively the cylinder head bolts, then hoist the cylinder head out of the block along with the exhaust manifold and the lower inlet manifold, being careful not to loosen it too much. Loose the gasket on the cylinder head and, when, wished, the exhaust manifold and lower inlet manifold may be removed off the cylinder head. Wipe the mating surfaces of the cylinder head and block using a rag and clean all traces of gasket and carbon, and no debris should be allowed to get into the oil and water passages. Should there be nicks or scratches on the head and block, it should be checked and in case of the suspicion of warpage, a straight-edge should be used to test. Be sure that the holes in the cylinder head bolts are oiled free and rotate the crankshaft so that Nos 1 and 4 pistons are slightly below their bores in order to prevent piston-to-valve contact. Install a new cylinder head gasket with the dowels (with exception of lower inlet manifold) and install exhaust manifold and lower inlet manifold as necessary, with the part number at the top. Insert the cylinder head and install the new bolts, and tighten the bolts in stages until the required torque is reached and then through stages until the required angles are met. Refit the lifting tackle to the right-hand lifting bracket of the engine, hold up the engine, and break the lifting tackle during the cylinder block. Re-fit the timing belt inner cover, camshaft cover, and camshaft sprocket and tighten the timing belt. Install the exhaust front section, secondary air injection pump, and pipes (where removed), coolant distribution housing, and re-attach the hoses. Reassemble the hose of the charcoal canister solenoid valve, the auxiliary drivebelt, spark plug HT leads, the wiring to the camshaft position sensor, the right-angled bracket and the auxiliary drivebelt tensioner. Re-wire all, re-assemble top of inlet manifold, replace cooling system and lastly re-assemble engine top cover.

Question 2

What are the steps involved in cylinder head dismantling and overhaul for 4-cylinder petrol engines on Audi 100?

Accepted Answer

Both ADR and non-ADR engines have a number of steps that are involved in cylinder head dismantling and overhaul. Start by unscrewing the battery negative lead and de-mounting the undershield of the engine compartment, and jacking the front of the car high as needed. Lift the engine top cover where applicable, then unscrew the nuts and remove the exhaust downpipe until it unconnection with the exhaust manifold, holding it on an axle stand, and retrieving the gasket. The next step involves unscrewing the nuts and bolts to take the exhaust manifold off of the cylinder head which drains the cooling system and coolant out of the engine by disconnecting the small hose that attaches to the thermostat housing. Disconnect different hoses and wires, such as the top hose at the coolant pipe, inlet manifold variable choke valve wiring and the ignition coil. Take away the inlet manifold, timing belt and cylinder head bolts in that order of tightening and lift the cylinder head off the block and the gasket. To refit, clean up the contact faces of the cylinder head and block, put a new gasket on the block and lower the head without going through jointing compound. Install and screw-in the cylinder head bolts and screw-in to the desired torque respectively. Reinstall parts of the timing belt, exhaust manifold and downpipe, clean up all the hoses and wiring by reconnecting them. Lastly, coolant, renew under shield and reconnect battery negative lead and make sure that the engine cover is replaced at the top as well.

Genuine Audi Cylinder Head

129 Cylinder Heads found

Audi Cylinder Head Part Number: 06M-103-062-AK

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Audi Cylinder Head Part Number: 06M-103-061-AK

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Audi Cylinder Head Part Number: 06E-103-065-B

Audi Cylinder Head Part Number: 06E-103-065-C

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Audi Cylinder Head Part Number: 06E-103-066-BX

Audi Cylinder Head Part Number: 06E-103-903-JX

Audi Cylinder Head Part Number: 078-103-265-JX

Audi Cylinder Head

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