Audi Workshop Service and Repair Manuals

Removing cylinder head

Special tools and workshop equipment required

t	Drip tray for workshop hoist -VAS 6208-

t	Counterhold tool -3036-

t	Two-arm puller -T40001-

t	Puller -T40039-

t	Hose clip pliers -V.A.G 1921-

t	Special wrench (Polydrive) -T10070-

Special tools and workshop equipment required

t  Pin wrench -T10020-

t  Locking pin -T40098- Removing l  Engine in vehicle.   Note t  All cable ties which are released or cut open when removing must be refitted in the same position when installing. t  If engine oil is contaminated, perform oil change → Booklet803. t  Before applying sealant, check updated information: → Parts catalogue –  Obtain code on vehicles with coded radio / radio and navigation system (RNS).

–  Pull off engine cover panel -arrows-.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-release fasteners -1- and -2- and take off front noise insulation. –  Drain off coolant → Chapter. –  Remove toothed belt → Chapter.

–  Loosen the camshaft sprocket bolt using counterhold -3036-.

–  Pull off camshaft sprocket using two-arm puller -T40001- with claw -T40001/6- and claw -T40001/7-.

–  Unbolt toothed belt cover (rear) from cylinder head -arrows-.

–  Unscrew earth cable -1-. –  Disconnect vacuum hose going to brake servo at bulkhead -2-. –  Disconnect ACF hose -3-.

–  Disconnect coolant hoses -1 and 2- and detach coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of coolant expansion tank.

–  Unplug electrical connector from charge pressure sender -G31--1-. –  Remove charge air hose (left-side) -2-.

–  Detach air intake hose -1- going to turbocharger (bottom right). –  Detach air intake hose -2- going to charge air cooler at lock carrier.

–  Detach electrical connectors -1 and 2- and move wire clear.

–  Unscrew oil supply pipe for turbocharger at cylinder block -1-. –  Unscrew bolt -2- of support for turbocharger.

–  Remove oil supply pipe for turbocharger -arrows-.

–  Remove oil return pipe -arrows- at turbocharger.

–  Loosen bolt -arrow- of support for turbocharger 2 turns. –  Remove intake manifold → Motronic direct injection and ignition system (4-cylinder); Rep. Gr. 24; Servicing injection system. –  Remove catalytic converter → Chapter. –  Remove cylinder head cover → Chapter.

–  Loosen cylinder head bolts, keeping to sequence shown.   Note Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached. –  Remove cylinder head. Installing cylinder head l  Tightening torques → Chapter „Cylinder head - exploded view“ → Chapter „Toothed belt drive - exploded view“   Note t  Renew the cylinder head bolts. t  On assembly, renew oil seals and gaskets as well as self-locking nuts and bolts that are tightened by turning through to a specified angle. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  If repairing, carefully remove any remaining gasket material from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. t  Carefully remove any remaining emery and abrasive material. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. t  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. t  For high-temperature paste refer to → Parts catalogue.   WARNING The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).   Note Apply spanner to central bolt of crankshaft for turning engine.

–  Align mark on camshaft sprocket with mark on toothed belt cover. The indentations -arrows- face each other. –  If crankshaft has been rotated: set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly.

–  Place cylinder head gasket in position. t  Note position of centring pins in cylinder block -arrows-. t  Note installation position of cylinder head gasket. Part No. should be legible from inlet side. –  Fit cylinder head. –  Insert and hand-tighten cylinder head bolts. –  Tighten bolts for cylinder head → Fig..   Note Cylinder head bolts do not have to be torqued down again later after repair work. –  Install cylinder head cover → Chapter. –  Install toothed belt → Chapter. –  Install poly V-belt → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install intake manifold → Motronic direct injection and ignition system (4-cylinder); Rep. Gr. 24; Servicing injection system. –  Connect battery → Electrical system; Rep. Gr. 27. –  Bleed fuel system → Motronic direct injection and ignition system (4-cylinder); Rep. Gr. 24; Servicing fuel injection system. –  Check oil level → Booklet803. –  Fill up with coolant → Chapter.   Note t  Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed. t  Contaminated or dirty coolant must not be used again. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Check headlight adjustment → Booklet803.   WARNING Never use battery charging equipment for boost starting. There is danger of damaging the vehicle's control units.