Audi Workshop Service and Repair Manuals

Removing and installing cylinder head cover Special tools and workshop equipment required

t  Puller -T40039- for vehicles with push-fitted ignition coils t  Sealant → Parts catalogue

Removing –  Take off engine cover panel -arrows-.

–  Unscrew bolt -arrow- and remove cover over coolant expansion tank.

–  Remove air pipe -arrows-.

–  Unplug electrical connector -arrow- at Hall sender -G40-. –  Remove toothed belt cover (top).

–  Remove turbocharger air recirculation valve -N249--item 4- and vacuum reservoir -2- from cylinder head cover. –  Detach vacuum line for solenoid valve 1 for activated charcoal filter -N80- from throttle valve housing. –  Unscrew bracket for vacuum line and move vacuum line clear. –  Disconnect crankcase breather hose from cylinder head cover.   Note Disregard items marked -1- and -3-.

–  Unscrew bracket for air intake pipe -arrows-.

–  Unscrew retaining strip for heat insulation sleeve -arrows-.

–  Disconnect earth cable -2-. –  Unplug electrical connectors -1-. –  Move wiring clear. Vehicles with bolted on ignition coils: –  Unbolt ignition coils -3-.

Vehicles with push-fitted ignition coils: –  Pull ignition coils out with puller -T40039-.

All vehicles: –  Unscrew nuts -arrows- and remove cylinder head cover. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew cylinder head cover gaskets if damaged. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Apply small quantity of sealant to sealing points -arrows- on top sealing surface of cylinder head; for sealant refer to → Parts catalogue.

–  Apply small quantity of sealant to sealing points -arrows- on top sealing surface of cylinder head; for sealant refer to → Parts catalogue.

–  First tighten inner cylinder head cover nuts, then tighten outer nuts in diagonal sequence. –  Make sure toothed belt cover (top) is correctly fitted. –  Install ignition coils → Rep. Gr.28.   Note Renew gaskets for bolted on ignition coils if damaged. Tightening torques

Component	Nm
Cylinder head cover to cylinder head	10
Retaining strip for heat insulation sleeve to cylinder head cover	10 1)
Bracket for air pipe to heat shield	23
Vacuum reservoir to cylinder head	10
Hose clips for air hoses	3.5
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue.