Audi Workshop Service and Repair Manuals

Removing and installing cylinder head cover

Removing –  Remove engine cover panel -arrows-.

–  Unfasten clips -arrows- and press toothed belt cover (top) to right side. –  Remove injectors and high-pressure pipe → Rep. gr.23.

–  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover.   Note Ignore items marked -2- and -arrows-.

–  Unplug electrical connectors on glow plugs → Rep. gr.28.

–  Unplug electrical connector -arrow- at position sender for charge pressure positioner -G581-.

–  Remove bolts -arrows- and place coolant return line to one side.

–  Remove bolts -arrows- and place fuel return line to one side.

–  Release hose clip -arrow- and detach fuel line from fuel rail.

–  Unplug electrical connector -arrow- at fuel pressure regulating valve -N276-.

–  Unplug electrical connector -B- at fuel pressure sender -G247-. –  Disconnect vacuum hose -A- from cylinder head cover. –  Disconnect wiring guide from fuel rail and move clear to one side. –  Detach vacuum lines from bracket at cylinder head cover.

–  Remove bolts -arrows- and detach fuel rail from cylinder head cover.

–  Slacken cylinder head cover bolts in the sequence -6 ... 1- and remove.

–  Detach cylinder head cover; to do this, unclip retaining tabs at rear cover for toothed belt -arrows-.   Note Disregard -items A, B-.

Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gasket for cylinder head cover and bolts for cylinder head cover if damaged or leaking. t  Renew grommets and seals for injectors if damaged or leaking. –  Tighten cylinder head cover bolts → Fig..

–  Make sure that cylinder head cover is clipped properly to toothed belt cover.   Note For illustration purposes, the installation position is shown with the camshaft sprocket removed. –  Use screwdriver to press clips -arrows- on toothed belt cover onto cylinder head cover until they engage with a click. –  Make sure there is a clearance between hub and toothed belt cover. –  Install coolant return line → Chapter. –  Install intake connecting pipe → Chapter. –  Install fuel rail, fuel return line and injectors → Rep. gr.23.