Audi Workshop Service and Repair Manuals

Removing cylinder head - vehicles with small engine support   Note

The engine support has to be removed and the engine supported from above in order to remove the cylinder head on vehicles with small engine support -version 1-.

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Diesel injection pump locking pin -3359-

t	Drip tray for workshop hoist -VAS 6208-

t	Counterhold tool -T10051-

t	Puller -T10052-

t  Crankshaft stop -T10100-

t  Angle driver -T10264-

t  Locking tool -T10265-

t  Engine bung set -VAS 6122-

Removing –  Remove particulate filter → Chapter. –  Remove cover -1- over battery; to do so, press release tab -arrow-.

Caution Observe notes on procedure for disconnecting the battery → Rep. gr.27. –  With ignition switched off, disconnect battery earth cable -arrow-.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank.

–  Remove front left wheel. –  Remove noise insulation (left-side) -fasteners 1 ... 3-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Lift retaining clip -arrow- and disconnect coolant hose from radiator.

–  Remove air hose (left-side) by lifting retaining clips -arrows- slightly.

–  Remove bolt -arrow- for air intake pipe (left-side).

–  Unscrew nut -1- and remove bracket with wiring from stud. –  Unclip bracket from wiring.

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Release clips on left and right -arrow A- and unclip air duct at bottom -2-. –  Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers -3-. –  Detach air pipe -1- from air duct (bottom) -arrow B-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Disconnect coolant hose at bottom of engine oil cooler -arrow- and drain off remaining coolant.

–  Remove battery → Rep. gr.27. –  Remove battery tray -arrows-.

–  Remove coolant hose between engine and radiator -arrows-.

–  Detach crankcase breather hose -2-. –  Move vent hose -4- and vacuum hoses -1- clear at air intake hose. –  Remove bolt -3-. –  Swing air hose to rear and detach from turbocharger.

Vehicles with manual gearbox: –  Detach securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal gate relay lever: –  Detach securing clip -4- for gate selector cable from gate relay lever -2- and pull cable off pin -arrow-.

Plastic gate relay lever: l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing. –  Pull locking device forwards onto stop -arrow 1- and lock by turning anti-clockwise -arrow 2-. –  Press gate relay lever towards front -arrow 3-.

All vehicles with manual gearbox (continued): –  Remove cable support bracket -arrows- from gearbox and place to one side (selector cables remain fitted).

All vehicles (continued): –  Unclip wiring clip -1-. –  Remove bolts -2- and -3-. –  Detach air pipe (left-side) from turbocharger by lifting retaining clip -4- slightly. –  Remove air pipe from engine compartment downwards.

WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Disconnect fuel supply hose -2- and fuel return hose -1- from fuel lines. –  Detach coolant hose -3-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Pull release tabs and disconnect fuel supply pipe -3- and fuel return pipe -2-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-. –  Detach coolant hose -1- at expansion tank. Vehicles with auxiliary heater: –  Disconnect fuel pipe (press release tab). –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-. –  Move fuel pipe clear. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

All vehicles (continued): –  Pull fuel filter upwards out of bracket -arrow- (hoses remain attached).

–  Unscrew bracket -3- for fuel filter. –  Unscrew bolt at filler neck -2- for washer fluid reservoir. –  Detach electrical connector at coolant expansion tank. –  Unscrew coolant expansion tank -1- and move clear to one side (hoses remain attached).

–  Unplug electrical connector -2- for exhaust gas temperature sender 1 -G235-.

–  Unplug electrical connector at exhaust gas recirculation cooler change-over valve -N345--arrow-. –  Set aside wiring harness leading to body.

–  Detach vacuum hose -2- from vacuum unit for charge pressure control. –  Detach vacuum hose -3- from line going to vacuum unit for change-over flap for exhaust gas recirculation. –  Disconnect vacuum line from tandem pump. –  Unclip exhaust gas recirculation cooler change-over valve -N345- from bracket. –  Move exhaust gas recirculation cooler change-over valve -N345- clear to one side (vacuum hoses remain attached). –  Detach oil supply hose -1- from turbocharger. –  Detach oil supply pipe going to oil filter bracket.

–  Unplug electrical connector at oil pressure switch -F1-. –  Unscrew oil pressure switch -1-. –  Detach oil supply pipe going to turbocharger at retaining clip -3- and at oil filter bracket -2-. –  Disconnect oil supply pipe at rear engine lifting eye. –  Detach oil supply pipe.

–  Disconnect vacuum hose -arrow- at brake servo.

–  Detach coolant hose -arrow- at coolant hose/pipe connection.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62- and move wiring clear.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Disconnect main connector for unit injectors and move wiring harness clear.

–  Unplug electrical connector -arrow- at fuel temperature sender -G81-.

–  Detach connector rail from glow plugs -arrows-.

–  Remove bolts -arrows-. –  Pull the guide tube for oil dipstick upwards out of cylinder block. –  Remove poly V-belt: vehicles with tensioner → Chapter, vehicles without tensioner → Chapter.

–  Vehicles with tensioner: remove bolts -arrows- and take off tensioner for poly-V-belt.

–  Set up support bracket -10-222 A- with adapters -10-222 A/3- and a total of 3 spindles on wing panel flanges as illustrated. –  Attach hooks of spindles to lifting eyes; the remaining spindle on the right side should not yet be attached. –  Take up weight of engine evenly with both spindles (but do not raise engine).

–  Remove bolts -1- and -2- and detach connecting bracket. –  Remove bolts -3 ... 6- and remove engine mounting.

–  Remove top toothed belt cover by releasing retaining clips -arrows-.

Vehicles with auxiliary heater: –  Remove exhaust pipe -3- for auxiliary heater → Rep. gr.82.   Note Disregard items marked -1- and -2-.

All vehicles (continued): –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Detach coolant hose -1- at exhaust gas recirculation cooler. –  Unbolt connecting pipe going to exhaust gas recirculation cooler -arrows-. Vehicles with auxiliary heater: –  Remove coolant pipes going to auxiliary heater from cylinder block (coolant hoses remain connected).

Vehicles with front-wheel drive: –  Remove nuts -1-, bolt -2- and banjo bolt -3-. –  Remove support for turbocharger together with oil return pipe.

All vehicles (continued): –  Unscrew bolts on flange between exhaust gas recirculation cooler and intake manifold.

–  Remove cover cap for vibration damper. –  Unbolt vibration damper; counterhold on centre bolt with ring spanner.

–  Unbolt toothed belt covers (bottom and centre) -arrows-.

–  Remove bolts -1 ... 3- for engine support.   Note To remove the bolts for the engine support, raise or lower the engine slightly as necessary via the spindles on support bracket -10 - 222 A-. –  Raise engine/gearbox assembly slightly via the two spindles and remove engine support. –  Lower the engine/gearbox assembly again.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Turn the crankshaft to TDC. l  The toothed segment -arrow- at camshaft sprocket must face upwards. l  The lug -1- on sender wheel for camshaft must align with the marking -2- on rear toothed belt cover (not fitted on all versions).   Note The camshaft sprocket is shown with the toothed belt removed for illustrative purposes. –  Lock hub with locking pin -3359-.

–  Lock crankshaft sprocket with crankshaft stop -T10100-. l  The markings on the sprocket -2- and the crankshaft stop -1- must align. The lug of the crankshaft stop must engage in the bore in the sealing flange.   Note The crankshaft stop can only be pushed onto the sprocket from the front face of the teeth.

–  Mark direction of rotation of toothed belt with chalk or felt pen. –  Loosen securing bolts for camshaft sprocket -arrows-.

–  Loosen securing nut -1- for tensioning roller. –  Turn the eccentric adjuster with the angle driver -T10264- anti-clockwise -arrow- until the tensioning roller can be secured with the locking tool -T10265-.

–  Now turn eccentric adjuster of tensioning roller clockwise -arrow- until stop and tighten securing nut -1- finger-tight. –  Take off toothed belt first from coolant pump and then from the remaining sprockets.

–  Remove locking pin -3359-. –  Unscrew bolts -arrows- for camshaft sprocket and remove camshaft sprocket from hub.

–  Loosen securing bolt for hub; use counterhold tool -T10051-. –  Then unscrew bolt approx. 2 turns.

–  Apply puller -T10052- and screw bolts -1- into hub. –  Remove hub by screwing in bolt -2- while counterholding at hexagon flats (30 mm) of puller.

–  Remove toothed belt tensioning roller. –  Remove bolts -2- and -4-. –  Unscrew bolt -3- and remove Hall sender -G40- from cylinder head. –  Unscrew stud -1- using two M8 locknuts.

–  Screw in bracket -T10014- into threaded hole above coolant pump. –  Attach spindle -1- of support bar -10-222 A- to bracket -T10014-. –  Lift engine using spindle -1- until spindles -2- and -3- are no longer carrying a load. –  Unhook spindles -2- and -3- and move to side.

–  Unscrew cylinder head cover bolts in the sequence -13 ... 1-. –  Remove bolts and take off cylinder head cover.

–  Follow the sequence for loosening the cylinder head bolts. –  Remove the cylinder head with the assistance of a 2nd mechanic. –  Lay cylinder head aside on a clean surface with the combustion chamber side facing upwards.   Caution t  Vehicles with ceramic glow plugs: The ceramic glow plugs fitted in this engine are very easily damaged and project slightly beyond the cylinder head gasket surface, so do NOT lay the cylinder head down on the gasket side while the glow plugs are still installed. t  Handling ceramic glow plugs → Chapter.