Audi Workshop Service and Repair Manuals

Removing cylinder head - vehicles up to approx. 05.2005   Note

On vehicles up to approx. 05.2005 (can be identified by engine support -version 1-), the engine support has to be removed and the engine supported from above before removing the cylinder head.

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-

t	Hose clip pliers -VAS 6340- or -VAS 5024 A-

t	Retainer -T10014-

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Hook (with spindle) -10-222 A/10-

t	Diesel injection pump locking pin -3359-

t	Pin wrench -T10020-

t	Crankshaft stop -T10050- for engines with circular crankshaft sprocket

t	Locking pin -T10060 A- or -T10060-

t	Locking pin -T10115-

t  Crankshaft stop -T10100- for engines with oval crankshaft sprocket

Procedure –  Lift engine cover panel at sides -arrows 1- and pull off towards front -arrow 2-.

–  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 centre noise insulation -fasteners 1 ... 3-.

–  Unplug electrical connector -2- from coolant temperature sender - radiator outlet -G83-. –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. –  Detach lower coolant hose -1-; to do so, pull out retaining clip.

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

–  Unplug electrical connector -arrow- for magnetic clutch of air conditioner compressor.

–  Detach lower air intake hose (left-side) from front air pipe by lifting retaining clip -2- slightly. –  Remove bolt -1-.   Note The coolant hose remains attached to bracket -arrow-.

–  Remove bolts -1- and -2-. –  Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

–  Detach air intake hose from turbocharger by lifting retaining clip -arrow- slightly.

–  Remove front cross-piece for underbody -arrows-.   Note To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°. –  Loosen nuts on clamp -1-.

–  Unbolt support for front exhaust pipe -arrows-.

–  Open clamp -arrow- and detach front exhaust pipe from turbocharger.

–  Unbolt bracket for exhaust system -arrows-. –  Push the clamp back and remove the front exhaust pipe.

–  Remove bolts -1- and -2- and detach bracket for turbocharger.   Note Place a cloth underneath to catch any escaping oil. –  Remove oil return pipe -3- at cylinder block.

–  Unscrew oil supply pipe at turbocharger and at exhaust manifold -arrows- and move to one side.

–  Unplug electrical connector -2- at air mass meter -G70-. –  Detach vent hose -1- and air hoses -3- and -5-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Unplug electrical connector -1- at oil pressure switch -F1-. –  Unscrew oil pressure switch -2-. –  Detach oil supply pipe at oil filter bracket -3- and at coolant pipe -4-.

–  Detach coolant hose -1- and move clear.   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. –  Detach fuel supply pipe -3- and fuel return pipe -2- and move clear. –  Remove air pipe by lifting retaining clips -arrows- slightly.

–  Detach electrical connector -arrow- at intake manifold flap motor -V157-. –  Unscrew bolts -1 ... 3- and detach intake manifold flap motor -V157-.

–  Disconnect vacuum hose -3- at exhaust gas recirculation valve -N18-. –  Detach pipe -4- for crankcase breather at air pipe. –  Release hose clip -1- at turbocharger using hose clip pliers -VAS 6340-. –  Move the vacuum hoses clear -arrow-. –  Unscrew bolts -2- and -5- and remove air pipe.

–  Unscrew mechanical exhaust gas recirculation valve -arrows-.

–  Disconnect hose going to vacuum unit for charge pressure control at separating point -arrow-.

–  Detach hose connection carrier -2- at solenoid valve block by releasing retaining tab. –  Detach vacuum hose -1- at non-return valve for brake servo.

–  Detach vacuum hose -arrow- going to brake servo at tandem pump.

–  Detach coolant hose -1- at cooler for exhaust gas recirculation.   Note Leave coolant hose -2- connected.

–  Detach electrical connector -arrow- at coolant temperature sender -G62- and move wire 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 coolant hoses at the connections indicated -arrows-.

–  Detach vacuum pipe -2- at vacuum reservoir. –  Unplug electrical connector -3- at charge air pressure sender -G31-. –  Detach coolant hose -5-. –  Unscrew bolts -1- and -4- and remove air pipe together with coolant hose.

–  Detach connector rail from glow plugs -arrows-.

–  Disconnect fuel supply pipe -3- and fuel return pipe -2- by pulling release tabs. –  Disconnect coolant hose -1- at expansion tank.

–  Release catches and pull fuel filter upwards out of bracket -arrow-.

–  Unscrew bracket -3- for fuel filter. –  Unscrew bolt at filler neck -2- for washer fluid reservoir. –  Detach electrical connector at coolant expansion tank. –  Unbolt coolant expansion tank -1- and remove.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  To slacken the poly V-belt, turn the tensioner in the direction of the -arrow-.

–  Lock tensioner for poly V-belt in position with locking pin -T10060 A- or -T10060-. –  Remove poly V-belt.

–  Remove tensioner for poly V-belt -arrows-.

–  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 detach engine mounting.

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

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

–  Unbolt lower and centre toothed belt covers -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 with 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 for cylinder No. 1. l  Toothed segment -arrow- in 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 Camshaft sprocket is shown in illustration with toothed belt removed. –  Lock hub on camshaft with locking pin -3359-.

–  Lock crankshaft sprocket using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket. l  The markings on the toothed belt sprocket and the crankshaft stop must align -arrow-. 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 pin wrench -T10020- anti-clockwise until the tensioning roller can be secured with the locking pin -T10115-.   Note Instead of using the pin wrench -T10020-, you can also use the 2-hole pin wrench -3387-.

–  Turn pin wrench -T10020- clockwise 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.

–  Remove cylinder head cover bolts in the sequence -13 ... 1-. –  Remove cylinder head cover. –  Unbolt engine lifting eye at front on cylinder head.

–  Follow the sequence for loosening the cylinder head bolts. –  Remove the cylinder head with the assistance of a 2nd mechanic.