Cylinder head, right, 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.

NOTE:

Secure all hose connections with correct hose clips (same as original equipment). See Parts catalog
Replace all cable ties which are opened or cut during removing in the same position when installing.
Replace cylinder head bolts.
Always replace seals, gaskets, self-locking nuts and bolts with specified tightening instructions.
When installing a new cylinder head or cylinder head gasket, drain all old coolant and re-fill with new coolant.

CAUTION: Always dispose of old coolant properly.

Drain coolant, see DRAINING .
Remove engine cover -arrows-.

Fig 1: Removing Engine Cover
Courtesy of AUDI OF AMERICA, INC.
Remove cylinder head covers -1- and -2-.
Remove intake air duct between air cleaner and throttle body.
WARNING:
- Fire hazard! Do not have anything in the area that can ignite fuel or fumes.
- Clean fuel connections and cover with rag to catch fuel spray.

Fig 2: Removing Intake Air Duct Between Air Cleaner And Throttle Body

G02724835

Courtesy of AUDI OF AMERICA, INC.

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

Fig 3: Disconnecting Fuel Supply And Return Lines

G02724836

Courtesy of AUDI OF AMERICA, INC.

Remove engine cover -arrows-

Fig 4: Removing Engine Cover
Courtesy of AUDI OF AMERICA, INC.
Remove cylinder head covers -1- and -2-.
Remove intake air duct to air duct to air cleaner.
WARNING: Fire hazard! Keep away anything that could ignite fuel or fumes. Clean connections before disconnecting. Cover with rag while disconnecting to prevent fuel spray.
Disconnect fuel supply and return lines -1-.
Disconnect hose -2-.

Fig 5: Disconnecting Fuel Supply And Return Lines

G02724838

Courtesy of AUDI OF AMERICA, INC.

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

Fig 6: Disconnecting Connector For Oxygen Sensor

G02724839

Courtesy of AUDI OF AMERICA, INC.

Disconnect connector -2-for oxygen sensor after Three Way Catalytic (TWC) converter and free wiring down to oxygen sensor.

Fig 7: Disconnecting Connector For Oxygen Sensor After Three Way Catalytic (TWC) Converter

G02724840

Courtesy of AUDI OF AMERICA, INC.

Remove toothed belt guard.
Disconnect connector -1- from Camshaft Position (CMP) sensor. See Fig 8.
Disconnect connector -2-.
Disconnect connector -3-.

Fig 8: Disconnecting Connector From Camshaft Position (CMP) Sensor
Courtesy of AUDI OF AMERICA, INC.
Remove toothed belt from camshafts, see TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS .
Remove idler wheel -1-.
Remove toothed belt cover -arrows-.

Fig 9: Removing Right Toothed Belt Cover

G02724842

Courtesy of AUDI OF AMERICA, INC.

Disconnect connectors -1- from ignition coils.
Remove bracket -2-.
Remove ignition coils -3-.
Disconnect crankcase breather hose.
Remove cylinder head cover.

Fig 10: Disconnecting Connectors From Ignition Coils

G02724843

Courtesy of AUDI OF AMERICA, INC.

Disconnect connector -1- for oxygen sensor for cylinder bank 5-8. See Fig 11.
Disconnect connectors -arrow- from fuel injectors of cylinder bank 5-8 and move wiring aside.
Disconnect connector for knock sensor for cylinder bank 1-4. See Fig 11.
Disconnect connectors from fuel injectors of cylinder bank 1-4.

Fig 11: Disconnecting Connector For Oxygen Sensor And Fuel Injectors

G02724844

Courtesy of AUDI OF AMERICA, INC.

Remove coolant line -arrows-.

Fig 12: Removing Coolant Line

G02724845

Courtesy of AUDI OF AMERICA, INC.

Remove hose -2-. See Fig 13.
Disconnect connector -1-.
Remove bracket -3-.
Disconnect connector -4-.
Disconnect ground cable -5- from cylinder head. See Fig 13.
Remove bolts -6-.
Disconnect hose -7- from combination valve.
Remove bolts -8-.
Disconnect connector -9-. See Fig 13.

Fig 13: Disconnecting Connectors, Hoses And Coolant Lines
Courtesy of AUDI OF AMERICA, INC.
Remove coolant line.
Remove intake manifold.
Loosen cylinder head bolt in numerical sequence.

Fig 14: Cylinder Head Bolt Loosening Sequence - Right Side
Courtesy of AUDI OF AMERICA, INC.
Remove cylinder head and place on soft surface.