audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

Removing cylinder head > < Removing and installing cylinder head cover
4-Cyl. TDI®Engine, Mechanics
Removing and installing cylinder head
Removing and installing intake manifold
 
A10-0659

Removing

  • ‒ → Pull dipstick -1- out of guide tube.
  • ‒ Unclipcaps.
  • ‒ Remove nuts -arrows- and detach engine cover.
  • ‒ Remove insulation lying below.
  • ‒ Re-insert dipstick into guide tube.

 
A13-0339
  • ‒ Unclipcaps.
  • ‒ → Remove bolts -arrows- and detach air cleaner cover.
 
A10-0746
  • ‒ → Screw out bolts -arrows-.
  • ‒ Remove air duct -1- and -2-.

 
A10-0756
  • ‒ → Disconnect vent hose -2- from air cleaner housing.
  • ‒ Unplug electrical connector -4- from air-mass meter.
  • ‒ Detach EGR valve -N18 from air cleaner housing -3-.
  • ‒ Detach wiring harness from air cleaner housing -arrow-.
  • ‒ Pull off air hose -5-.
  • ‒ Screw out bolt -1-.
  • ‒ Detach air cleaner housing.

Vehicles with manual gearbox

  • ‒ Remove EGR connecting pipe -item26-29.

Vehicles with automatic gearbox:

  • ‒ Remove EGR system cooler => Page 26-48.
 
A15-0512

All models:

  • ‒ → Detach air hose -1-.
  • ‒ Disconnect vacuum hoses -2- and -3-.
  • ‒ Screw out bolts -arrows-.
  • ‒ Detach intake manifold.

Installing

Install in reverse order, paying attention to the following:

Notes:

  • ◆ Always replace gaskets and self-locking nuts.
  • ◆ Pay attention to fitting position of intake manifold gasket.
  • ◆ Hose connections and hoses for charge-air system must be free from oil and grease before fitting.

Vehicles with automatic gearbox:

  • ‒ Install EGR system cooler => Page 26-53.

Tightening torques

Component

Nm

Intake manifold to cylinder head

25

EGR connecting pipe to

Intake manifold

25

Exhaust manifold


25

Clamps for air hoses

3.5

Removing cylinder head > < Removing and installing cylinder head cover