Audi Workshop Service and Repair Manuals

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

t  Hose clip pliers -V.A.G 1921- t  Sealant → Parts catalogue

Removing –  Remove bonnet → Chapter. –  If fitted, unclip bracket -1-. –  Take off engine cover panel -arrows-. –  Remove noise insulation beneath cover.

–  Lever off caps -3 and 4- on two-piece windscreen wiper arm with a screwdriver. –  Slacken nuts on two-piece windscreen wiper arm a few turns. –  Release arms -1 and 2- one after the other by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off two-piece windscreen wiper arm.   Note Use puller (commercially available) to remove wiper arm if necessary.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4 and 5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-.

–  Unscrew nuts and bolts -arrows-. –  Pull fresh air duct forwards and remove by turning it to right side of vehicle.

–  Detach air hose -1- from intake manifold; to do this, release retaining clip -2--arrow-, if fitted. –  Move air hose to front.

–  Disconnect crankcase breather hose -4- at cylinder head cover.   Note Disregard -items 1 ... 3-.

–  Remove toothed belt cover (top section) -arrows-.

–  Remove cylinder head cover bolts in the sequence -11 ... 1-.   Note Disregard -arrows-. –  Detach bracket with fuel pipes. –  Remove cylinder head cover. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gasket for cylinder head cover if damaged. t  Renew cylinder head cover bolts if gasket is damaged. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. Do NOT use lubricant.

–  Apply one drop of sealant (Ø approx. 5 mm) to each sealing point at front bearing cap/cylinder head -arrows-; for sealant refer to → Parts catalogue.

–  Apply one drop of sealant (Ø approx. 5 mm) to each sealing point at rear bearing cap/cylinder head -arrows-; for sealant refer to → Parts catalogue.

–  Tighten bolts for cylinder head cover to final torque in the sequence -1 ... 11-.   Note Disregard -arrows-. –  Install air pipes/hoses with plug-in connectors → Chapter. Tightening torques

Component	Nm
Cylinder head cover to cylinder head	10
Engine cover panel to bracket	5.5