Cylinder Head, Removing And Installing: Removing

WARNING: This page is about a different car, the 2009 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

The engine is installed.

NOTE:

The following information describes how to remove both cylinder heads at the same time.

If only one cylinder head will be removed, follow the applicable instructions in the following description.

WARNING:

There is a risk of injury because the fuel is under very high pressure.

Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.

-- Reduce the fuel pressure in the high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

-- Remove the upper coolant pipe. Refer to UPPER COOLANT PIPES, REMOVING AND INSTALLING .

-- Remove the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Remove the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION WITH FUEL RAIL, REMOVING AND INSTALLING .

Fig 1: Disconnecting Fuel Injector Connectors

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-- Disconnect the connectors on the fuel injectors.

-- Remove the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

Vehicles without a secondary air injection system:

Fig 2: Identifying Nuts, Bolt And Left Catalytic Converter

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-- Remove the left front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Remove the nuts -arrows- and the bolt -1-.

-- Remove the left catalytic converter from the exhaust manifold and lay it aside.

NOTE:

The installation location is shown with the engine removed.

-- Remove the right front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Remove the nuts -arrows- and the bolt -1- and move the catalytic converter to the side.

Fig 3: Identifying Nuts, Bolts And Right Catalytic Converter

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NOTE:

The installation location is shown with the engine removed.

Continuation for all vehicles:

Fig 4: Counterholding Coolant Pump Pulley Using Pin Wrench 3212

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-- Remove the bolts for the coolant pump ribbed belt pulley, using a Wrench - Pin Type 3212 to counterhold.

-- Remove the bolts -1- and -2- and lay the power steering pump aside.

Fig 5: Dynamic Steering Installation Location

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NOTE:

The illustration shows the installation location on a vehicle with dynamic steering.

Ignore -item 3- and -arrow-.

-- Disconnect the connector -3- for the Engine Coolant Temperature Sensor -G62-.

Fig 6: Disconnect Electrical Connector For Engine Coolant Temperature ECT Sensor

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-- Remove the bolts -1, 2, 4 and 5- on the front coolant pipe.

NOTE:

Ignore the -arrows-.

-- Remove the protective plate -1- for the high pressure line -arrows-.

Fig 7: Identifying Nuts -Arrows- And Protective Plate -1-

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Fig 8: High Pressure Line Bolts

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WARNING:

There is a risk of injury because the fuel is under very high pressure.

Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.
To reduce remaining residual pressure, place clean cloth around the connector and carefully loosen connector.

-- Reduce the fuel pressure in the high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

-- Remove the threaded connection -1- and the union nuts -2- and -3-.

-- Remove the bolts -arrows- on the retaining plates and the high pressure line.

-- Remove the threaded connection -2- and move the fuel supply line to the side.

Fig 9: Identifying High-Pressure Fuel Pump Components

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-- Disconnect the connectors -1- and -6-.

NOTE:

Ignore -items 3, 4 and 5- and -arrow-.

-- Disconnect the right and left electrical connectors -arrows- on the camshaft adjuster actuators.

Fig 10: Disconnecting Right And Left Electrical Connectors On Camshaft Adjuster Actuators

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-- Remove the bolts -1- and -2- and free up the electrical wiring harness.

-- Remove the cylinder head cover. For the left side. Refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING and for the right side refer to RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Disconnect the connector -3- on the Camshaft Position Sensor -G40-.

Fig 11: Disconnect Electrical Connector On Camshaft Position

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-- Remove the ground cable bolt -4-.

NOTE:

Ignore -item 1, 2 and 5-.

-- Remove the left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and the bracket for the left connectors.

Fig 12: Cylinder Bank 2 Oxygen Sensor Electrical Connectors

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NOTE:

Ignore items -1 and 4-.

-- Remove the bolts -arrows- and the bracket for the right connectors.

Fig 13: Identifying Bolts -Arrows- And Right Connector Bracket

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NOTE:

Ignore items -1 and 4-.

-- Remove the bolt -arrow- and remove the oil dipstick with the guide tube.

Fig 14: Identifying Oil Dipstick Guide Tube Bolt

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-- Remove the vacuum hose from the vacuum pump -arrow- and free it up.

Fig 15: Identifying Vacuum Pump Hose

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-- Remove the bolts -arrows- on the rear of the cylinder head.

Fig 16: Identifying Bolts At Rear Of Cylinder Head

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Left cylinder head: 3 bolts.
Right cylinder head: 4 bolts

NOTE:

The cams on the intake camshaft partially restrict access to the cylinder head bolts, such as bolts -1- and -2- shown in this example .

Fig 17: Intake Camshaft Partially Restrict Access To Cylinder Head Bolts, Such As Bolts Shown In This Example

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The slider on the camshaft must be pressed in the direction of -arrow A- using a plastic wedge to remove the bolt -1-.

The slider on the camshaft must be pressed in the direction of -arrow B- using a plastic wedge to remove the bolt -2-.

CAUTION:

Risk of damage.

The camshaft slider must only slide in the base-circle phase, that is the rocker arm on the slider that will be moved must not be loaded with a cam. When loosening the cylinder head bolts, follow the sequence described in the following instruction.

There is a risk of it breaking.

The camshaft sliders must not slide on the thin ribs.

-- Insert the Crankshaft Socket T40058 guide pins as follows:

Fig 18: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Rotate the crankshaft in the direction of engine rotation -arrow- using the Crankshaft Socket T40058 until the camshaft position shown in the following illustration is reached.

Fig 19: Identifying TDC With Special Tool Adapter T40058

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The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine as shown in the illustration.

Fig 20: Identifying Exhaust Camshaft Openings Alignment
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Left cylinder head:

Fig 21: Slide Unloaded Camshaft Slide As Far As Stop In Direction

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-- Slide the unloaded camshaft slider -B- as far as the stop in the direction of the -arrow-.

Right cylinder head:

Fig 22: Slide Unloaded Camshaft Slide As Far As Stop In Direction

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-- Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Continuation for both cylinder heads:

Fig 23: Identifying TDC With Special Tool Adapter T40058

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-- Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the Crankshaft Socket T40058.

The threaded holes -arrows- in the camshafts must face upward.

Fig 24: Identifying Camshaft Threaded Hole Alignment
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Left cylinder head:

Fig 25: Identifying Bolt (Left Cylinder Head)

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-- Remove the bolt -1-.

Right cylinder head:

Fig 26: Identifying Bolt (Right Cylinder Head)

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-- Remove the bolt -2-.

Continuation for both cylinder heads:

Fig 27: Identifying TDC With Special Tool Adapter T40058

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-- Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the Crankshaft Socket T40058.

The openings -arrows- on the exhaust camshafts must face toward the outer side of the engine.

Fig 28: Identifying Exhaust Camshaft Openings Alignment
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Left cylinder head:

Fig 29: Slide Unloaded Camshaft Sliders As Far As The Stop In Direction Of -Arrow-

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-- Slide the unloaded camshaft sliders -B- and -C- as far as the stop in the direction of the -arrow-.

Right cylinder head:

Fig 30: Slide Unloaded Camshaft Sliders As Far As The Stop In Direction Of -Arrow-

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-- Slide the unloaded camshaft slider -F- as far as the stop in the direction of the -arrow-.

Continuation for both cylinder heads:

Fig 31: Identifying TDC With Special Tool Adapter T40058

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-- Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using the Crankshaft Socket T40058.

The threaded holes -arrows- in the camshafts must face upward.

Fig 32: Identifying Camshaft Threaded Hole Alignment
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-- Remove the camshaft timing chains from the camshafts. Refer to CAMSHAFT TIMING CHAIN, REMOVING FROM CAMSHAFTS .

CAUTION:

Risk of damaging valves and piston crowns.

If the camshaft timing chain was also only removed on one cylinder head, the crankshaft must not be rotated any more.

Left cylinder head:

Fig 33: Identifying Bolts -3 Through 9- And Unloaded Camshaft Slider -A-

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-- Remove the bolts -3 through 9- while sliding the unloaded camshaft slider -A- accordingly.

-- Remove the cylinder head.

Right cylinder head:

Fig 34: Identifying Bolts -10 Through 16- And Unloaded Camshaft Sliders -D- & -E-

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-- Remove the bolts -10 through 16- while sliding the unloaded camshaft sliders -D- and -E- accordingly.

-- Remove the cylinder head.