Audi A8 2003 Workshop Manual page 165

8-cylinder TDI engine (4.2 ltr. 4-valve common rail), mechanics - Edition 12.2013
– Loosen cylinder head bolts in the sequence shown.
– Remove cylinder head bolts and carefully detach cylinder
head.
Note
To prevent damage to glow plugs, always place cylinder head on
a soft foam surface after removal.
– Detach electrical connectors at glow plugs.
– Remove intake manifold (left or right) ⇒ Rep. gr. 23 .
– Remove exhaust gas recirculation cooler
Installing
Note
The cylinder heads of diesel engines must not be machined.
♦
Renew the cylinder head bolts.
♦
Renew self-locking nuts and bolts when performing assembly
♦
work.
Renew bolts which are tightened to a specified angle as well
♦
as oil seals and gaskets.
If repairing, carefully remove any remaining gasket material
♦
from the cylinder head and cylinder block. Ensure that no long
scores or scratches are made on the surfaces.
Carefully remove any remaining emery and abrasive material.
♦
No oil or coolant must be allowed to remain in the blind holes
♦
for the cylinder head bolts in the cylinder block.
Do not remove new cylinder head gasket from packaging until
♦
it is ready to be fitted.
Handle gasket very carefully. Damage to the silicone coating
♦
or the indented area will lead to leaks.
Position cylinder head gasket on dowel sleeves. The word -
♦
oben- (top) or the Part No. must face towards cylinder head.
The plastic protectors fitted to protect the open valves should
♦
not be removed until the cylinder head is ready to be fitted.
When installing an exchange cylinder head with fitted cam‐
♦
shafts, oil the contact surfaces between the roller rocker fin‐
gers and cams.
After working on the valve gear, turn the engine carefully at
♦
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
Secure all hose connections with the correct type of hose clips
♦
(same as original equipment) ⇒ Electronic parts catalogue .
When fitting a new cylinder head or cylinder head gasket, drain
♦
off all the old coolant and refill with new coolant.
⇒ page 320 .
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A8 2003 ➤
2. Removing and installing cylinder head
159