Cylinder head, left, removing: Notes

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2004 Audi A6, 2003 Audi S6, 2003 Audi A6, 2002 Audi S6, and 2002 Audi A6. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

DO NOT re-use fasteners that are worn or deformed in, normal use.
Some fasteners are designed to be used only once and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.
To prevent contact corrosion, use only approved nuts, bolts and washers, etc. These fasteners have a special coating and are identified by green coloring.

NOTE:

Secure all hose connections with original equipment hose clamps.
Always replace opened or cut ties wraps in the same position when installing.
Replace cylinder head bolts.
Replace seals, gaskets, self-locking nuts and bolts which have specified tightening instructions.
When installing a new cylinder head or cylinder head gasket, drain all old coolant and re-fill with new coolant. See COOLING SYSTEM, DRAINING AND FILLING .

Unbolt guide tube for oil dipstick from cylinder head.

Fig 1: Identifying Bolt Guide Tube For Oil Dipstick

G02724818

Courtesy of AUDI OF AMERICA, INC.

Remove engine cover -arrows-.
Remove cylinder head covers -1- and -2-.
Remove intake air duct for air cleaner.
WARNING:
- Fire hazard! Do not have anything in the area that can ignite fuel of fumes.
- Clean fuel connections and cover with rag to catch fuel spray.

Fig 2: Removing Engine Cover

G02724819

Courtesy of AUDI OF AMERICA, INC.

Disconnect fuel supply and return lines -1-.
Disconnect hose -2-.

Fig 3: Disconnecting Fuel Supply And Return Lines

G02724820

Courtesy of AUDI OF AMERICA, INC.

Remove upper bolt between exhaust manifold and exhaust pipe.
Disconnect connector for left oxygen sensor -arrow- and move wiring aside.

Fig 4: Disconnecting Connector For Left Oxygen Sensor -Arrow-

G02724821

Courtesy of AUDI OF AMERICA, INC.

Disconnect connector -2- for oxygen sensor and free wiring to oxygen sensor.

Fig 5: Disconnecting Connector For Oxygen Sensor

G02724822

Courtesy of AUDI OF AMERICA, INC.

From below remove bolts -arrows- between exhaust manifold and exhaust pipe.

Fig 6: Removing Bolts Between Exhaust Manifold And Exhaust Pipe

G02724823

Courtesy of AUDI OF AMERICA, INC.

Remove exhaust pipe from retainer -arrow-.

Fig 7: Removing Exhaust Pipe From Retainer

G02724824

Courtesy of AUDI OF AMERICA, INC.

Loosen double clamp -1- and move it forward.

Fig 8: Locating Double Clamp
Courtesy of AUDI OF AMERICA, INC.
Carefully remove exhaust pipe.
CAUTION: DO NOT bent swivel joint of exhaust pipe by more than 10° to prevent damage.
Remove toothed belt guard.
Disconnect connector -2-. See Fig 9.
Disconnect connector -3-.

Fig 9: Disconnecting Connectors At Front Of Engine
Courtesy of AUDI OF AMERICA, INC.
Remove toothed belt from camshafts, see TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS .
Remove camshaft sprocket for cylinder bank 5-8.
Loosen bolts -1-.
Remove bolts -2- and remove toothed belt cover.

Fig 10: Removing Toothed (Timing) Belt Cover Bolts - Left Side

G02724827

Courtesy of AUDI OF AMERICA, INC.

Disconnect hose -1-. See Fig 11.
Remove bolts -2-.
Disconnect connector -3-.
Remove bolt -4- and remove oil pipe.
Remove bolts -5- and take out combination valve.

Fig 11: Removing Combination Valve

G02724828

Courtesy of AUDI OF AMERICA, INC.

Remove coolant line -arrows-.

Fig 12: Removing Coolant Line

G02724829

Courtesy of AUDI OF AMERICA, INC.

Disconnect hose -1-. See Fig 13.
Disconnect hose -2-. See Fig 13.
Remove bracket -3-. See Fig 13.
Disconnect connectors -4- from ignition coils. See Fig 13.
Remove ignition coils -5-.
Disconnect connector -6-.
Remove cylinder head cover.

Fig 13: Removing Cylinder Head Cover

G02724830

Courtesy of AUDI OF AMERICA, INC.

Disconnect connector -1- for knock sensor, cylinder bank 5-8. See Fig 14.
Disconnect connectors -arrows- from injectors, cylinder bank 5-8, and move wiring harness clear. See Fig 14.
Disconnect connector for knock sensor, cylinder bank 1-4. See Fig 14.
Disconnect connectors from injectors, cylinder bank 1-4. See Fig 14.

Fig 14: Disconnecting Connector For Knock Sensors And Fuel Injectors

G02724831

Courtesy of AUDI OF AMERICA, INC.

Disconnect connector -1-. See Fig 15.
Disconnect hose -2-. See Fig 15.
Remove bolts -8-. See Fig 15.
Disconnect connector -9-.
Remove coolant pipe.
Remove intake manifold.

Fig 15: Removing Intake Manifold

G02724832

Courtesy of AUDI OF AMERICA, INC.

Loosen cylinder head bolts in sequence shown.
Remove cylinder head and place on suitable soft surface.