Audi Workshop Service and Repair Manuals

Removing and installing cylinder head cover (right-side)

Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Remove cover -1- at right of engine compartment. –  Unscrew bolts -2- and detach air duct from air cleaner housing -3-.

–  Unfasten screw connections -arrows- and detach engine cover panels -A ... C-.

–  Unscrew hose connections and bolt connections on the air duct at the points indicated by -arrows- and remove the air duct.   WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection.

–  Disconnect fuel supply pipe -1- and fuel return pipe -2-. –  Detach hose -3- leading to activated charcoal filter solenoid valve 1 -N80-. –  Move hose and wiring clear.

–  Unplug electrical connector at output stage -N122--item 3- and at output stage 2 -N192--item 4-. –  Unplug electrical connector -5- at air mass meter -G70-. –  Move wiring harness at air cleaner housing clear. –  Unplug vacuum hose -1-. –  Unscrew nut -2- and remove air cleaner housing with air mass meter -G70-.   Note Disregard -item 6-.

–  Loosen quick release fasteners -arrows- and remove cover for cylinder head cover (right-side).

–  Remove bolt -1-. –  Remove top right air pipe; disconnect hose connections -2- and -3- for this purpose.

–  Unscrew bolts -arrows- and remove bracket.

–  Unplug electrical connectors -3 ... 5-. –  Remove ignition coils. –  Unfasten cable tie and move wiring clear. –  Disconnect crankcase breather hose -2- at cylinder head cover. –  Detach vacuum hose -1- from combination valve for secondary air system.

–  Unscrew bolt -3- at toothed belt cover (right-side). –  Unscrew nuts -1- and -2- and remove cylinder head cover. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew cylinder head cover gaskets if damaged. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Fit all cable ties in the original positions when installing.

–  Apply small quantity of sealant to sealing points -arrows- on top sealing surface of cylinder head; for sealant refer to → Parts catalogue.

–  Tighten inner nuts -1- for cylinder head cover. –  Then tighten outer nuts -2- in stages and in diagonal sequence. –  Tighten bolt -3-. Tightening torques

Component		Nm
Cylinder head cover to cylinder head		10
Toothed belt cover to cylinder head cover		10
Ignition coils to cylinder head cover		10
Bracket to:	Toothed belt cover	10
	Bracket	10
Air pipe to cylinder head cover		10
Fuel supply line to fuel rail		22
Air duct to intake manifold		10
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5.5