Audi Workshop Service and Repair Manuals

Removing cylinder head - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB Special tools and workshop equipment required

t  Removal lever -80 - 200-

t  Counterhold tool -3036-

t  Puller -T10320-

Removing –  Drain coolant → Chapter. –  Remove timing chain from camshaft on relevant 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 and toothed belt tensioner → Rep. gr.23. –  Loosen bolt -1- for toothed belt drive sprocket approx. 2 turns using counterhold tool -3036-.

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

–  Remove bolts -arrows-; toothed belt cover (rear) remains in installation position.

–  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 marked -1, 4- and -arrows-.

–  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-.

–  Release clamp -arrow- and detach connecting pipe -1- for exhaust gas recirculation.

Cylinder head (right-side): –  Remove intermediate pipe (right-side) → Chapter. –  Remove coolant pipe (top right) → Chapter. –  Unscrew bolts -arrows- and remove protective plate for high-pressure pipe. –  Remove union nuts -1- and -4-, move high-pressure pipe clear and remove.   Note Disregard -items 2, 3-.

–  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 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.