Audi Workshop Service and Repair Manuals

Removing cylinder head - engine code CAPA

Special tools and workshop equipment required

t	Counterhold tool -3036-

t	Puller -T10320-

t	Puller -T40064-

t  Removal lever -80 - 200-

Removing –  Drain coolant → Chapter. –  Remove timing chain from camshaft on relevant side → Chapter. –  Remove relevant intermediate pipe: left-side → Chapter; right-side → Chapter. –  Remove intake manifold (top section) → Rep. gr.23. –  Remove relevant cylinder head cover: left-side → Chapter; right-side → Chapter.

Cylinder head (left-side): –  Remove toothed belt for high-pressure pump → Rep. gr.23. –  Unscrew nut -1- for high-pressure pump shaft using counterhold tool -3036-. –  Remove damper weight.

–  Remove toothed belt sprocket for high-pressure pump using puller -T40064-.

–  Loosen bolt -1- for toothed belt drive sprocket approx. 2 turns using counterhold tool -3036-.

–  Remove toothed belt drive sprocket using puller -T10320-.

–  Unscrew bolts -arrows- and remove toothed belt cover (rear).

–  Remove bolt -2- for dipstick guide tube.   Note Disregard -item 1-.

–  Remove union nuts -2- and -3-, move high-pressure pipe clear and remove.   Note Disregard -items 1, 4-.

–  Detach T-piece from coolant bleeder hose -arrow-.

–  Unplug electrical connector -1- at intake manifold flap motor 2 -V275--item 4-.   Note Disregard -items 2, 3- and -arrow-.

–  Unscrew bolts -arrows- and remove connecting pipe -1- for exhaust gas recirculation.

Cylinder head (right-side): –  Remove coolant pipe (top right) → Chapter. –  Unscrew union nuts -1 ... 4- and detach high-pressure pipes.

–  Remove bolts -1- and -2- for engine lifting eye and pump for exhaust gas recirculation cooler -V400-. –  Use removal lever -80 - 200- and move wiring harness clear -arrow-.

–  Disconnect coolant bleeder pipe -arrow-. –  Unplug electrical connectors at glow plugs for cylinders 2 and 3.

–  Unplug electrical connector -1- at intake manifold flap motor -V157-.   Note Disregard -arrows-.   Note

Lay a cloth under the connection to catch escaping fuel.   Caution Protect fuel system against contamination. Rules for cleanliness when working on the injection system → Chapter. –  Disconnect fuel supply hose -1- and fuel return hose -2-.

–  Loosen union nuts -1- and -2-. –  Remove bolts -arrows- and move fuel rail to one side (fuel hoses remain connected).

Continuation for both sides: –  Slacken cylinder head bolts in the sequence -1 ... 8-. –  Remove bolts and carefully take off cylinder head.   Caution Risk of damage to glow plugs when putting down cylinder head. After removal, the cylinder head must not be put down on the gasket side with the glow plugs still installed, because the glow plugs project slightly beyond the gasket surface.