Removing cylinder head -engine codes ABK, ADA, ADW- — AUDI

AAE ABB ABK ADA ADW
Note:

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

Observe or obtain radio code on vehicles with coded radio.
Disconnect earthing strap at battery with ignition switched off.
Drain coolant => Page
19-4
.

Unscrew exhaust manifold/front exhaust pipe nuts -arrow-.

Unbolt exhaust system at bracket -arrow-.
Push exhaust system towards the rear so that studs on exhaust manifold are free.

Note:

Note electrical wiring of lambda probe.

Remove the upper toothed belt guard -arrows-.

Set crankshaft to TDC mark for cylinder No. 1 -arrows- by turning central bolt on crankshaft toothed belt sprocket in direction of engine rotation...

...at the same time the marking on the camshaft sprocket must align with the marking on the toothed belt guard. If necessary, rotate crankshaft 1 additional turn.

Loosen toothed belt system with TORX key T45 -arrow below-.
Press toothed belt tensioner downwards.
Take toothed belt off camshaft sprocket.
Unscrew Torx bolt and pivot tensioner plate forwards.

Note:

Mark the running direction with chalk or a felt-tipped pen before removing the ribbed belt. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

Loosen the bolts -1-, -2- and -4- by at least one turn.
Release belt tension on V-belt or ribbed belt with tensioner nut -3-.
Remove V-belt or ribbed belt from alternator belt pulley.
Unscrew the bolt -2- and swing the alternator towards the left.
Unscrew the 2 engine lifting eyelet bolts.

Unbolt the earth connection point on the left side of the cylinder head -arrow-.

Unplug the connectors at:

1 -
Coolant temperature sensor -G62
2 -
Sensor for coolant temperature display -G2, and coolant temperature switch (too hot) -F14

Unplug spark plug connectors and lay aside.

Detach the coolant hoses on the left side of the cylinder head -arrows-.

Detach throttle cable -2- at throttle valve connection and support bracket (do not remove retainer). Move throttle cable to the side.
Detach the vacuum pipe -1- to the brake servo unit.
Unplug connectors -arrows- at the injectors.
Unplug connectors at fan run-on thermoswitch.
Lay wiring aside.
Detach crankcase breather hose.

Detach the air duct hose -2- from the throttle valve unit and the air flow meter, loosen hose clamps -arrows- for this purpose.
Detach the elbow piece -1- from hose to cylinder head cover/intake manifold.
Detach the heat shield for the throttle valve potentiometer at the side of the throttle valve body.

Detach coolant hose -1- from the connection at rear of cylinder head.
Unscrew earth wire -2- at cylinder head cover.
Unbolt rear crankcase ventilation pipe from the cylinder head.

Disconnect wires/unplug connectors:

1 -
Throttle valve potentiometer -G69
2 -
Connection on throttle valve unit to activated carbon filter solenoid valve 1 -N80
3 -
Cold start valve -N17
4 -
Connection on throttle valve unit to intake air preheater
-
Idling switch -F60

Important
The fuel system is pressurised. Before opening the system place a cloth around the connection point. Then release pressure by carefully loosening the connection.
Disconnect fuel supply and return lines at the bolted connection -arrow-.
Unscrew fuel supply and return lines from cylinder head cover.

Detach hose of intake air preheater from warm air arrester plate on exhaust manifold.

Unscrew the nuts for the cylinder head cover.
Remove reinforcement strips, bracket, toothed belt guard and cylinder head cover.
Maintain sequence when loosening cylinder head bolts.
Remove cylinder head.