Audi Workshop Service and Repair Manuals

Removing and installing cylinder head cover (right-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-. –  Disconnect vacuum line -1-.

–  Remove air cleaner housing → Rep. gr.23. –  Unplug electrical connector at glow plug for cylinder 1.

–  Unplug electrical connectors -1 ... 7- and use removal lever -80 - 200- to move electrical wiring clear.

–  Mark high-pressure pipes to ensure they are re-connected to the same injectors.   Caution Protect fuel system against contamination. Rules for cleanliness when working on the injection system → Chapter. –  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.

–  Pull release pins upwards -arrow- and pull return line connections off injectors. –  Remove pressure retention valve -1- from retainer and move clear to one side with fuel hoses connected.   Note

The next illustrations show the left-side cylinder head cover. –  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. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. –  Clean sealing surfaces; they must be free of oil and grease. –  Tighten bolts for cylinder head cover in diagonal sequence and in stages. –  Install injectors, high-pressure pipes, air cleaner housing and exhaust gas pressure sensor 1 -G450- → Rep. gr.23. –  Check fuel system for leaks → Chapter.