Cylinder head, removing and installing: Removing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.

CAUTION: Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure → Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention! . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Fig 1: Identifying Front Engine Cover

GW00017827

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove front engine cover - arrows -.

Fig 2: Identifying Bolts & Air Duct

GW00017848

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.
Drain coolant → Cooling system, draining and filling .
Remove both front wheels.

NOTE:

Secure the brake disc with a wheel bolt.

Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Bring lock carrier into service position →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.
Remove upper part of intake manifold → 24 - FUEL INJECTION SYSTEM .

Fig 3: Separating Fuel Line

GW00017849

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel line - arrow -.

Fig 4: Removing Low Pressure Line, Thereby Removing Bolts And Union Nuts

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove low pressure line, thereby removing bolts and union nuts - 1 through 6 -.
Remove intake manifold lower part → 24 - FUEL INJECTION SYSTEM .
Disconnect electrical harness connectors at fuel injectors.
Remove ribbed belt → Ribbed belt, removing and installing

Remove front coolant pipe → Front coolant line, removing and installing .

Left cylinder head:

Remove power steering pump → 48 - STEERING .
Remove oil filter housing → Oil filter housing, removing and installing .

Right cylinder head:

Fig 5: Disconnecting Vacuum Hose At Vacuum Pump

GW00017887

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum hose - 1 - at vacuum pump.

NOTE:

Ignore - arrows -.

Continued for both sides:

Fig 6: Removing Nuts & Left Front Exhaust Pipe With Catalytic Converter

GW00017875

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nut - 2 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which is accessible from top.

NOTE:

To improve clarity, the removed engine is shown from the rear.

Fig 7: Removing Heat Shield For Left Drive Axle

GW00017992

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield - arrows - for left drive axle.

Right cylinder head and vehicles with automatic transmission:

Remove right drive axle from transmission flange shaft.

Fig 8: Locating Clamping Sleeves

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Continued for both sides:

Separate exhaust system at relevant clamping sleeve - arrows - and push clamping sleeve toward rear.

Fig 9: Removing Nuts & Left Front Exhaust Pipe With Catalytic Converter

GW00017875

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 1 - and - 3 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which are accessible from bottom.

NOTE:

To improve clarity, the removed engine is shown.

Disconnect front exhaust pipe from exhaust manifold.

Fig 10: Disconnecting Electrical Harness Connector For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

GW00017854

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - for oxygen sensor before catalytic converter on relevant side and free up wiring.

NOTE:

Ignore - 2 -.

Left cylinder head:

Fig 11: Disconnecting Electrical Connector

GW00017993

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 2 -.

NOTE:

Ignore - 1 - and - arrows -.

Fig 12: Removing Bolt And Pulling Oil Dipstick Guide Tube Upward And Out

GW00017994

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrow - and pull oil dipstick guide tube upward and out.

All:

Remove cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .
Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
Remove camshaft timing chains from camshafts → Detaching timing chains from camshaft, removing and installing chain tensioner .

Fig 13: Removing Bolts At Rear Of Cylinder Head

GW00017995

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - at rear of cylinder head.

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

Fig 14: Identifying Cylinder Head Bolts Loosening Sequence

GW00017713

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Follow sequence - 1 to 8 - when loosening cylinder head bolts.
Carefully remove cylinder head.