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 -1-.

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Spring type clip pliers -VAS 5024 A-

t	Drip tray for workshop hoist -VAS 6208-

t	Retainer -T10014-

t	Counterhold tool -T10051-

t	Puller -T10052-

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

t	Diesel injection pump locking pin -3359- (2x)

t	Pin wrench -T10020-

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

t	Locking pin -T10060 A-

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

t  Locking pin -T10115- t  Safety goggles t  Protective gloves Procedure   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off.

Engine cover panel (version 1): –  Pull dipstick -1- out of guide tube. –  Lift engine cover panel at sides -arrows 2- and pull off towards front -arrow 3-. –  Re-insert dipstick in guide tube.

Engine cover panel (version 2): –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

All vehicles (continued): –  Remove engine compartment seal from lock carrier and wing panel flanges. –  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct (bottom) together with air hose.

–  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.

–  Remove bolts -1- and -3-. –  Move vacuum hoses at rear intake pipe clear to one side. –  Disconnect hose -2- for crankcase breather system at air pipe. –  Release spring clip -4- with spring clip pliers -VAS 5024 A- and detach air pipe at connection for turbocharger.   Note Shown from rear with engine removed for illustration purposes.   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-.

–  Remove noise insulation (left and right) -fasteners 1 ... 3-. –  Unbolt drive shafts (left and right) from gearbox flange and centre bearing. –  Tie up the left drive shaft. –  Remove front exhaust pipe → Chapter.

–  Remove bolts -1- and -2- and detach support 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 exhaust manifold -arrows-.

–  Unplug electrical connector -2- at charge pressure sender -G31-/intake air temperature sender -G42-. –  Remove bolt -4-. –  Remove front air pipe with air hose by lifting retaining clips slightly -1- and -3-.

–  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.

–  Unscrew bolts -1 ... 3- and remove pendulum support.

–  Remove air intake hose (right-side) by lifting retaining clips -arrows- slightly.   Caution Seal opening of charge air cooler with a piece of clean foam or similar to prevent coolant from entering.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Pull out retaining clip at the bottom -arrow- and disconnect coolant hose from radiator.

–  Also detach upper coolant hose on oil cooler -arrow-, and drain off remaining coolant. –  Then remove the coolant hose completely.

–  Detach hose (rear) from exhaust gas recirculation cooler -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- at tandem pump and at brake servo.

–  Detach coolant hoses at the connections indicated -arrows-.

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

–  Detach bracket for engine cover panel from cylinder head -arrow-.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62-.

Caution Rules for cleanliness when working on the injection system → Chapter.   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- (white marking) and fuel return hose -1- (blue marking) from tandem pump.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Detach main connector for unit injectors and glow plugs. –  Move wiring harness clear.

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

–  Remove air intake hose at intake manifold flap by lifting retaining clip -1- slightly. –  Detach electrical connector -2- at intake manifold flap motor -V157-.

–  Detach coolant hoses -1- and -2- at front of engine.

–  Remove bolts -arrows-. –  Pull guide tube for oil dipstick upwards out of the cylinder block and swing towards front to remove.

–  Detach vacuum hose -1-. –  Unscrew bolt -2- and detach vacuum reservoir from bracket.

Caution Rules for cleanliness when working on the injection system → Chapter.   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 pipe -2- and fuel return pipe -1- by pulling release tabs.

Fuel filter - version 1: –  Lift fuel filter out of bracket -arrow- with hoses connected and move it aside.

Fuel filter - version 2: –  Slacken bolt -1- one turn. –  Remove bolt -2- and nut -3-. –  Move fuel filter aside with hoses attached.

All vehicles (continued): –  Unscrew bracket -3- for fuel filter. –  Unscrew bolt at filler neck -2- for washer fluid reservoir. –  Unscrew coolant expansion tank -1- and move clear to one side with the lines attached.

–  Detach fuel hose -4-. –  Unclip bracket -3- for fuel hoses on left engine lifting eye. –  Remove bolts -1- and -2-. –  Remove coolant reservoir and fuel filter together with the pipes.   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. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt.

–  Lock poly V-belt tensioner using locking pin -T10060 A-. –  Remove poly V-belt.

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

–  Place support bracket -10 - 222 A- with adapters -10 - 222 A /3- and 3 spindles on wing panel flange as shown in the illustration. –  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-.

–  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 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.   Note At TDC position the toothed segments -arrows- face upwards. –  Lock hubs with locking pin -3359- (2x).

–  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 pin of the crankshaft stop must engage in the aperture 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 sprockets -arrows-.

–  Loosen securing nut -1- for tensioning roller. –  Turn eccentric adjuster of tensioning roller anti-clockwise using pin wrench -T10020- until tensioning roller can be secured with locking pin -T10115-.

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

–  Remove locking pins -3359-. –  Remove securing bolts -arrows- for camshaft sprockets. –  Remove the camshaft sprockets from hubs.

–  Loosen securing bolt -1- for hub on inlet camshaft; use counterhold tool -T10051-.

–  Loosen securing bolt -1- for hub on exhaust camshaft; use counterhold tool -T10051-. –  Unscrew securing bolts of hubs approx. 2 turns.

–  Fit puller -T10052- on hub of inlet camshaft and screw bolts -arrows- into hub. –  Remove hub by screwing in bolt -1- while counterholding at hexagon flats (30 mm) of puller.

–  Fit puller -T10052- on hub of exhaust camshaft and screw bolts -arrows- into hub. –  Remove hub by screwing in bolt -1- while counterholding at hexagon flats (30 mm) of puller. –  Remove toothed belt tensioning roller.

–  Remove bolts -2 ... 4-. –  Unscrew bolt -5- 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 -11 ... 1-. –  Remove cylinder head cover.

–  Remove bolts -1-, -3- and -5-. –  Unscrew bolts -2- and -4- alternately in several stages.   Note Do not pull bolts out of rocker arm shaft so that components remain attached to shaft. If necessary mark position on rocker arm. –  Detach rocker arm shaft. –  Remove bolts -6 ... 10-.

–  Follow the sequence for loosening the cylinder head bolts. –  Lift out cylinder head with the help 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 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.