Audi Workshop Service and Repair Manuals

Removing and installing cylinder head cover (left-side)

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Open end spanner insert, AF 17 -V.A.G 1331/6-

t	Puller -T10055- with -T10055/1-

t	Socket -T40055-

Removing –  Remove engine cover panel -arrows-.

–  Remove intake manifold (top section) → Rep. gr.23.

–  Disconnect coolant hose -3- from coolant expansion tank. –  Remove bolts -arrows- and move coolant expansion tank to side with coolant hoses -1- and -2- attached.

–  Remove oil filler neck. To do so, lift tab -1- and turn oil filler neck anti-clockwise -arrow-.

Caution Protect fuel system against contamination. Rules for cleanliness when working on the injection system → Chapter. –  Pull release pins upwards -arrow- and pull return line connections off injectors.

–  Remove electrical connector -1- for Lambda probe -G39- from bracket and unplug connector. –  Move electrical wiring clear. –  Remove bolt -arrow- and detach bracket for connector for Lambda probe -G39-.

–  If fitted, disconnect vacuum line -arrow-.

–  Unplug electrical connectors at glow plugs for cylinders 4 and 5. –  Unplug electrical connectors -1 ... 4-. –  Use removal lever -80 - 200- and move wiring harness clear.

–  Mark high-pressure pipes to ensure they are re-connected to the same injectors. –  Loosen union nuts for high-pressure pipes -1 ... 6- using tool insert, AF 17 -V.A.G 1331/6- and socket -T40055- and detach high-pressure pipes.

–  Remove bolts -arrows- for cover plates for injectors. –  Pull cover plates upwards and turn through 90°.

–  Remove bolts -arrows- for injectors.

Caution Used injectors must always be re-installed on the same cylinder. Identify cylinder numbers on corresponding injectors. –  Pull out injectors using puller -T10055- with adapter -T10055/1-.

–  Loosen bolts -arrows- on cylinder head cover in diagonal sequence. –  Remove bolts and take off cylinder head cover. Installing Installation is carried out in the reverse order; note the following: l  Tightening torque → Chapter „Cylinder head cover - exploded view“   Note t  Renew gasket for cylinder head cover if damaged. t  Renew bolts for cylinder head cover if seals on bolts are damaged. –  Clean sealing surfaces; they must be free of oil and grease. –  Tighten cylinder head cover bolts → Fig.. –  Install injectors and high-pressure pipes → Rep. gr.23. –  Install intake manifold (top section) → Rep. gr.23. –  Check fuel system for leaks → Chapter.