Audi Workshop Service and Repair Manuals

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

t  Ring spanner -3035- Removing   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off. –  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. –  Take off camshaft sprocket (right-side). –  Remove intake manifold (front section) → Rep. Gr.23.

–  Remove toothed belt cover (rear right) -arrows-. –  Unscrew guide tube for dipstick at cylinder head and lift off. –  Remove right exhaust manifold together with intermediate pipe → Chapter.

–  Remove heat shield above turbocharger -arrows-. –  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 hoses -arrows- at turbocharger and mechanical exhaust gas recirculation valve.

–  Remove air intake hose -arrows-.

–  Unplug electrical connectors -1 ... 3-. –  Detach electrical connector -4- at injection pump. –  Unplug electrical connector -5- at coolant temperature sender. –  Detach electrical connectors at glow plugs. –  Move wiring harness clear.

–  Unplug electrical connector -arrow- at engine mounting (right-side). –  Move wiring harness clear.

–  Unplug connector -arrow- and move wire for needle lift sender -G80- clear to the side.

–  Detach oil pipe -1- at turbocharger. –  Unscrew oil pipe at intake manifold -2-.

–  Remove bolts -2- and -3-. –  Press coolant pipe (right-side) -1- to rear and set down.   Note Illustration shows coolant pipe with oil filter bracket removed.

–  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.