Audi Workshop Service and Repair Manuals

Removing cylinder head - engine codes AEB, AJL Special tools and workshop equipment required

t  Locking pin -T40011- for vehicles from 06.1999 onwards Procedure l  Lock carrier must be in service position → Rep. Gr.50.   Note Fit all cable ties in the original positions when installing.

Caution To prevent damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect earth wire -arrow- from battery terminal → Rep. Gr.27. –  Drain coolant → Chapter. –  Remove intake manifold → Chapter. –  Remove poly V-belt and tensioner for poly V-belt → Chapter.

–  Detach air cleaner cover -arrow-.

–  Unplug electrical connectors: 1 -  On charge pressure control solenoid valve -N75- 2 -  On activated charcoal filter solenoid valve 1 -N80- 3 -  On output stage -N122- 4 -  On air mass meter -G70- –  Move wiring harness clear and lay on top of engine. –  Detach hose connections and remove air cleaner housing -arrows-.

–  Unplug electrical connector -1- at coolant temperature display sender -G2-/coolant temperature sender -G62-. –  If fitted, unplug electrical connector -2- at temperature sender -G18-. –  Unclip/release all electrical wires on the cylinder head and move clear.

–  Remove crankcase breather pipe -1-. –  Remove bolts -2- for oil supply pipe. –  Remove heat shield -3-. –  Remove bolts -4- for turbocharger. –  Detach coolant hose for heat exchanger at rear of cylinder head (release retaining clip on connecting flange).

–  Remove toothed belt cover (top section)   Caution Irreparable damage can be caused if the toothed belt slips. Turn crankshaft only in direction of engine rotation (in clockwise direction). –  Rotate crankshaft to “TDC” by turning bolt for toothed belt sprocket. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to “TDC”-arrows-.

Vehicles up to 05.1999: –  Loosen TORX bolt -bottom arrow- and press toothed belt tensioner down. –  Remove toothed belt from camshaft sprocket. –  Remove TORX bolt and swivel bracket of tensioner towards front.

Vehicles from 06.1999 onwards:   Caution Risk of damage to toothed belt tensioner. The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure. –  Applying constant and moderate force, apply hexagon key through opening -2- to press toothed belt tensioning roller -1- anti-clockwise -arrow- until piston can be locked with locking pin -T40011-. –  Insert locking pin -T40011- and make sure that it remains in place.   Note Bolt -3- must not be slackened. –  Remove toothed belt from camshaft sprocket. All vehicles (continued): –  Remove cylinder head cover → Chapter.

–  Remove cylinder head bolts in the sequence: -1 ... 10-. –  Take off cylinder head.