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Removing and installing cylinder head cover (left-side) > < Removing and installing cylinder head

A4 Mk2

Cylinder head - exploded view of components
   
Cylinder head - exploded view of components
  Note
t  Never set down cylinder head on workbench, as this could damage injectors and glow plugs.
t  A pressure limiting valve (for lubrication points in cylinder head) is screwed into each cylinder head. Tightening torque: 25 Nm.
1 - Cylinder head
q   Removing: left-side → Chapter; right-side → Chapter
q   Checking for distortion → Fig.
q   Cylinder heads must not be machined on diesel engines
q   Installing → Chapter
q   If renewed, refill system with fresh coolant
2 - Gasket for cylinder head cover
q   Renew if damaged or leaking
q   Before fitting gasket apply sealant at sealing points → Chapter „Removing and installing cylinder head cover (left-side)“, → Chapter „Removing and installing cylinder head cover (right-side)“
3 - Cylinder head bolt
q   Renew
q   Note sequence when loosening: cylinder head (left-side) → Anchor, cylinder head (right-side) → Anchor
q   Note correct sequence when tightening → Anchor
4 - Cylinder head cover
q   Removing and installing: left-side → Chapter, right-side → Chapter
q   Renew cylinder head cover if injector seals are damaged
5 - Deflector ring
q   Renew if damaged
6 - Seal
q   Renew if damaged or leaking
7 - Filler cap
8 - Injector pipes
q   Use ring spanner -3035- for removal
q   Always remove pipework complete
q   Do not alter shape
q   Tighten to 30 Nm
9 - Return pipe
10 - Seal
q   Renew
11 - Banjo bolt, 5 Nm
12 - Intake manifold
q   Removing and installing → Rep. Gr.23
13 - 10 Nm
q   Tighten in stages and in diagonal sequence
14 - Gasket
q   Renew
15 - Dowel sleeve
q   2x
q   Take care to prevent dowel sleeves dropping into intake ports
16 - 10 Nm
q   Tighten in stages and in diagonal sequence
17 - Heat shield for exhauster pump
q   Depending on version
18 - 10 Nm
19 - Exhauster pump
q   For brake servo
q   Removing and installing → Fig.
20 - O-rings
q   For exhauster pump
q   Renew
21 - Cylinder head gasket
q   Different thicknesses
q   Note marking → Fig.
q   Renewing → Chapter
q   Installation position: Part No. towards cylinder head
q   If renewed, refill system with fresh coolant

   
Checking cylinder head for distortion
–  Use straight edge and feeler gauge to measure for distortion at several points.
l  Max. permissible distortion: 0.1 mm
  A15-0280
Identification of cylinder head gasket
-Arrow 1- = holes
-Arrow 2- = Part No.
-Arrow 3- = production control code (can be disregarded)
  Note
t  Cylinder head gaskets of different thicknesses are fitted depending on the amount of piston projection → Chapter.
t  Fit new gasket with same identification if only gasket is renewed.
  A13-0143
Removing and installing exhauster pump
–  Remove bolts -1- for exhauster pump on cylinder head (left-side) and turn pump in direction of -arrow-.
–  Fit new O-rings.
l  Tightening torque: 10 Nm.
  A13-0114

Removing and installing cylinder head cover (left-side) > < Removing and installing cylinder head