Audi Workshop Service and Repair Manuals

Removing cylinder head - vehicles up to 09.2005 Special tools and workshop equipment required

t  Counterhold tool -3036-

t  Puller -T40064-

Removing –  Drain off coolant → Chapter. –  Move lock carrier to service position → Chapter. –  Remove toothed belt for high-pressure pump → Rep. gr.23. –  Loosen central nut -1- for high-pressure pump shaft using counterhold tool -3036-. –  Remove damper weight.

–  Remove tensioning roller for toothed belt for high-pressure pump -arrow-.

–  Use puller -T40064- to pull off belt sprocket for high-pressure pump.

–  Remove bolts -arrows- and detach toothed belt cover (rear).

Cylinder head (right-side): –  Disconnect fuel supply line -2- and fuel return line -1- from high-pressure pump and move lines clear to the side. Continuation for both sides: –  Remove intake manifold (top section) → Rep. gr.23. –  Remove bottom section of intake manifold (left or right) → Rep. gr.23. –  Remove timing chain from camshaft → Chapter on relevant cylinder bank. –  Remove intermediate pipe: left-side → Chapter, right-side → Chapter. –  Remove cylinder head cover (left or right) → Chapter.

Cylinder head (right-side): –  Remove bolts -1- and -2-. –  Pull coolant pipe (right-side) forwards out of cylinder block and detach coolant pipe.

Continuation for both sides: –  Loosen cylinder head bolts in the sequence shown. –  Remove bolts and carefully detach cylinder head.   Caution After removal, the cylinder head must not be put down on the gasket side with the glow plugs still installed, because the glow plugs project beyond the gasket surface.   Note Audi A4 models with a 2.7 or 3.0 ltr. TDI engine are always equipped with steel glow plugs.