Audi Workshop Service and Repair Manuals

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

t  Ring spanner -3035- Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Drain off coolant → Chapter. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50. –  Detach toothed belt from camshaft sprockets → Chapter. –  Remove intake manifold (front section) → Rep. Gr.23.

–  Lift off centre section of rear toothed belt cover -2-. –  Unscrew bolts -arrows- and detach rear left toothed belt cover -3- and rear right toothed belt cover -1-.

–  Disconnect both coolant hoses -arrows-. –  Remove bolts -1- and -2-. –  Pull off coolant pipe towards the front. –  Remove front exhaust pipe with main catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Remove starter catalytic converter: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Remove left exhaust manifold together with intermediate pipe → Chapter. –  Unplug electrical connector at injection pump. –  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-.

Vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC: –  Unbolt mechanical exhaust gas recirculation valve from left section of intake manifold -2-.   Note Disregard items marked -1- and -3-.

–  Disconnect coolant hoses -1- and -2- at coolant pipe. –  Remove bolt -3-.   Note Illustration shows coolant pipe with engine removed.

–  Slacken securing bolt -arrow- of coolant pipe (left-side).   Note Illustration shows coolant pipe with turbocharger removed. –  Pull coolant pipe to rear out of cylinder block. Vehicles with engine code letters BDG, BDH: –  Remove top coolant pipe (left-side) → Chapter.

All vehicles: –  Detach electrical connectors at glow plugs. –  Unfasten cable clamp at cylinder head cover (left-side) and move wiring harness clear to one side. –  Disconnect return pipe from injectors -1-. –  Unscrew nuts -arrows- for cylinder head cover and detach cylinder head cover.

–  Slacken cylinder head bolts in the sequence indicated and remove bolts. –  Take off cylinder head and place it on a soft surface (such as foam plastic).   Caution Never set down cylinder head on workbench, as this could damage injectors and glow plugs.