Cylinder Head, Removing And Installing: Removing

During installation, install all heat insulation sleeves at the same locations.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the upper front coolant pipes. Refer to UPPER FRONT COOLANT PIPES, REMOVING AND INSTALLING .

-- Remove the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the left coolant pipes. Refer to LEFT COOLANT PIPES, REMOVING AND INSTALLING .

-- Remove the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Remove the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the resonator -1-.

Fig 1: Identifying Resonator With Bolts

Courtesy of AUDI OF AMERICA, LLC

Vehicles with SCR System:

Fig 2: Identifying EGR Temperature Sensor

Courtesy of AUDI OF AMERICA, LLC

-- Remove the connector -2- for the EGR Temperature Sensor -G98- from the bracket, disconnect it and free up the wire.

Vehicles with Parking Heater:

Courtesy of AUDI OF AMERICA, LLC

-- Lift the clamps -1 and 2-, loosen the hose clamps -3-, and remove the coolant hoses.

-- Remove the nuts -arrows- and the coolant pipes.

Continuation for All Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connectors and free up the wires.

For the Exhaust Gas Temperature Sensor 4 -G648-
For the Exhaust Gas Temperature Sensor 3 -G495-
For the Exhaust Gas Temperature Sensor 2 -G448- (installed depending on the emissions standard)

-- Remove the connector -4- for the Heated Oxygen Sensor -G39- from the bracket, disconnect it and free up the wire.

AWD Vehicles:

-- Remove the EGR cooler. Refer to EGR COOLER, REMOVING AND INSTALLING .

FWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

Use the Hook Tool: T40207 to disconnect the connector -item 2- in the figure below . Disconnect the securing pin on the connector housing -1- -arrow-.

-- Loosen the hose clamp -1- and remove the air duct hose.

Courtesy of AUDI OF AMERICA, LLC

-- Push the heat shield boot aside, disconnect the connector -2- and free up the wire.

Continuation for All Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the double bolt -1-, push the coolant pipe slightly toward the rear.

-- Remove the bolts -2-, and push the emissions control module and on FWD vehicles the EGR cooler rearward.

-- Remove the bolt -2- and union nut -4-.

Fig 3: Identifying Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -3 and 5- and the oil return pipe.

-- Remove the bolt -2- and only loosen the bolts -1, 3, and 4-.

Fig 4: Emissions Control Module Bracket - Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

Vehicles with Camshaft Adjustment:

Fig 5: Identifying Hose Clamp

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connectors -1 and 3-.

-- Loosen the hose clamp -2-.

Continuation for All Vehicles:

Fig 6: Identifying Connectors

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connectors and free them up:

1 - For the Charge Air Temperature Sensor after Charge Air Cooler -G811-

3 - For the Charge Air Pressure Sensor -G31-

4 - For the Charge Air Temperature Sensor In Front Of Charge Air Cooler -G810-

5 - For the Throttle Valve Control Module -J338-

-- Remove the bolts -2 and 7- and remove the coolant hose -6-.

-- Place the left front coolant pipe aside.

-- Remove the bolt -1- for the oil dipstick tube.

Fig 7: Identifying Oil Dipstick Guide Tube Bolt

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -2 and 3- for the intake manifold bracket.

Vehicles with Camshaft Adjustment:

-- Remove the Throttle Valve Control Module -J338-. Refer to Throttle Valve Control Module -J338-, REMOVING AND INSTALLING .

Continuation for All Vehicles:

Fig 8: Identifying Cover Bolt

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -3-.

-- Remove the bolt -1- and leave the cover -2- in the installation position.

-- Release the retainer -arrow- and remove the vacuum hose -1-.

Fig 9: Identifying Retainer

Courtesy of AUDI OF AMERICA, LLC

-- Remove the vacuum hose -2-.

-- Remove the bolt -3-.

Depending on the vehicle, there are different components.

-- Disconnect the connector -2- for the Engine Coolant Temperature Sensor - G62-.

Fig 10: Identifying Hose Clamp

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the hose clamp -1- and remove the coolant hose.

-- Remove the vacuum hose -3-.

-- Disconnect the connector for the glow plug. Refer to GLOW PLUG, REMOVING AND INSTALLING .

Fig 11: Identifying Pliers 3314 Positioned With Groove

Courtesy of AUDI OF AMERICA, LLC

-- Move the wiring harness to the side.

-- Loosen the cylinder head bolts in the sequence -1 to 10-.

Courtesy of AUDI OF AMERICA, LLC

A second technician is needed to remove the cylinder head.

-- Move the cylinder head from the rear toothed belt guard toward the left and remove the tensioning roller at the same time.

-- Be careful not to damage the turbocharger oil return line.

-- Lay the cylinder head down being careful not to bend the oil return line. Place a piece of wood under the exhaust manifold if necessary.

Do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface.