Removing and installing right cylinder head cover: Audi A8 D2 (ACK, AKF, ALG, AMX, …)

🧭 Before you start

Fits: Audi A8 D2 (4D)

• Opens: fuel
• Renewed: gaskets

Don't miss

• Seal off inlet connections with clean cloths.
• The distributor housing does not have to be completely removed.
• Provide support for connections at injectors when unfastening union nuts for injector pipes.
• The injectors can only be removed in certain camshaft positions.Crank engine at crankshaft central bolt.
• (Arrow) points in direction of travel.

🔧 Engine codes this applies to

📋 Procedure

1. Pull lock carrier forwards .
2. Detach engine cover (arrows).
3. Remove cover on right in engine compartment (arrows).
4. Unfasten hose clamp (1).
5. Remove air cleaner housing (arrows).

6. Remove top air pipe (arrows). [Note: Seal off inlet connections with clean cloths.]
7. Unscrew union nut (1) at distributor housing.
8. Screw out bolts (2) and (3). [Note: The distributor housing does not have to be completely removed.]
9. Unplug connectors (1) and (3).
10. Unscrew union nuts (5 ... 8). [Note: Provide support for connections at injectors when unfastening union nuts for injector pipes.]
11. Screw out bolts (2) and (4).
12. Unplug connectors from glow plugs.
13. Set down rail element on intake manifold.
14. Unplug connectors (2 ... 7).
15. Unscrew and lay bare wiring harness (arrows).
16. Whilst pressing retaining clips, detach return pipe (1) at injectors.
17. Disconnect fuel pipe (1) at T-piece.
18. Disconnect fuel pipe (2) at fuel pre-supply pump. To do so, press catch and lift off pipe (arrows).
19. Disconnect fuel pipes at points marked with (arrows).
20. Set down fuel pipes on intake manifold.
21. Unscrew oil filler neck.
22. ⚠ The engine is only to be turned at the crankshaft in the direction of engine rotation (clockwise). — Crank engine until bolt is visible through recess at camshaft (arrow). [Note: The injectors can only be removed in certain camshaft positions.Crank engine at crankshaft central bolt.]
23. Unscrew covers for injectors (arrows).
24. Pull covers upwards and give 1/4 turn (90°).
25. Unscrew injectors (arrows).
26. ⚠ Mark assignment of injectors to cylinder.Used injectors are only to be re-installed at the same cylinder. — Pull out injectors for cylinders (1) and (3). [Note: (Arrow) points in direction of travel.]
27. Screw puller T40059(Item 1) onto injector to be removed and knock out injector using multi-purpose toolVW 771(Item 2).
28. Give the crankshaft a further 1/ 2 turn (180°) in clockwise direction.
29. Pull out injectors for cylinders (2) and (4). [Note: (Arrow) points in direction of travel.]
30. Diagonally slacken off bolts (arrows) for cylinder head cover.
31. Screw out bolts and detach cylinder head cover. [Note: Replace gaskets and seals.Re-attach all cable ties in the same locations on installation.Secure all hose connections with standard clamps Parts catalogue.Remove and replace copper seals beneath injectors.Replace gaskets for cylinder head cover if damaged.]
32. Remove residual sealant from sealing surfaces and degrease.
33. Insert half-round gasket (1).
34. Apply ∅ approx. 3 mm sealant bead to half-round gasket such that it projects approx. 5 mm at both ends (right arrow).
35. Apply a droplet of sealant to all cylinder head/bearing cap transitions Parts catalogue (∅ approx. 5 mm).
36. Apply ∅ approx. 3 mm sealant bead to roughly half way up the bearing caps (arrows).
37. Diagonally tighten cylinder head cover bolts.
38. Install injectors 23.
39. Use torque wrenchV.A.G 1331 with open ring spanner attachmentV.A.G 1331/8 for tightening injector pipe. [Note: Provide support for connections at injectors when tightening union nuts for injector pipes.]
40. Alternatively, use can be made of torque wrenchV.A.G 1331 with ratchetV.A.G 1331/1 and 14 mm socket wrench3150. [Note: Heed the following on assembly: Pull catch outwards and press fuel pipe (2) onto fuel pre-supply pump connection until it engages (arrow).If the pipe has been fitted properly, the catch will be loosely positioned in the hose coupling.(Item 1), (Item 3) and (Item 4) can be ignored.]
41. Install lock carrier with attachments General body repairs, exterior50.
42. Install headlights Electrical system94.
43. Install front bumper General body repairs, exterior63.
44. Check headlight adjustment Electrical system94.

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