Audi Workshop Service and Repair Manuals

Removing and installing cylinder head cover (left-side) Special tools and workshop equipment required

t  Ring spanner -3035-

t  Torque wrench -V.A.G 1331- with 17 mm attachment (commercially available) t  Sealant → Parts catalogue

Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Remove intake manifold (front section) → Rep. Gr.23. –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank to one side (coolant hoses -1 ... 3- remain attached). –  Unfasten cable clamp at cylinder head cover and move wiring harness clear to one side. –  Mark position of retaining clips on injector pipes (e.g. with felt-tip pen). –  Mark injector pipes according to cylinder (e.g. with felt-tip pen). –  Disconnect injector pipes one by one with ring spanner -3035-.

–  Disconnect return pipe from injectors -1-. –  Unscrew nuts -arrows- for cylinder head cover and detach cylinder head cover. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals for return pipes. t  Renew cylinder head cover gaskets if damaged. t  Renew cylinder head cover if injector seals are damaged. t  Fit all cable ties in the original positions when installing.

–  Clean sealing surfaces; they must be free of oil and grease. –  Fit semi-circular seal -1-. l  Installation position: Parts number should be visible from outside; straight side of sealing surface should be flush with sealing surface of cylinder head. –  Draw a bead of sealant (Ø approx. 3 mm) over the semi-circular seal so that about 5 mm projects out at both ends -right arrow-.

–  Apply a drop of sealant (Ø approx. 5 mm) to all sealing points at joints between cylinder head and camshaft bearing caps. –  Draw a bead of sealant (Ø approx. 3 mm) up to about half the height of camshaft bearing caps. –  Tighten nuts for cylinder head cover diagonally and in stages. –  Fit injector pipes one at a time, working from bottom to top and secure using torque wrench -V.A.G 1331- and 17 mm attachment (commercially available).   Note t  Ensure stress-free installation of injector pipes. t  Make sure that retaining clips are positioned correctly. –  Install intake manifold (front section) → Rep. Gr.23. Tightening torques

Component		Nm
Cylinder head cover to cylinder head		10 → Note
Return pipes to injectors		5
Injector pipes to:	Injectors	30
	Injection pump	30

1)  Re-tighten to 10 Nm when engine is warm.