Removing cylinder head - vehicles with engine code letters AJM — AUDI

🧭 Before you start

Fits: Audi A6 C5 (4B)

• Special tools named: 30 mm spanner, puller

Don't miss

• Do not bend the flexible joint (de-coupling element) in the exhaust system more than 10°, otherwise it could be damaged.
• Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.
• Refrigerant circuit of air conditioner must not be opened. — Unbolt air conditioner compressor from bracket.
• Illustration shows engine removed.
• Use 30 mm spanner to hold puller.

🔧 Engine codes this applies to

📐 49 workshop diagrams for AJM

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ On vehicles with telematics, activate service mode of telematics control unit before disconnecting battery Radio, telephone, navigation01Telematics self-diagnosis. — Obtain code on vehicles with coded radio / radio and navigation system (RNS).
2. Detach rubber seal from plenum chamber cover in direction of (arrow).
3. Detach plenum chamber cover (1) to front.
4. With ignition switched off, disconnect earth wire (arrow) at battery.
5. ⚠ Hot steam/hot coolant may escape when opening expansion tank; cover filler cap with cloth and open carefully. — Open filler cap on coolant expansion tank.

6. Pull dipstick (1) out of guide tube.
7. Unclip cover caps.
8. Unfasten nuts (arrows) and detach engine cover.
9. Remove insulation beneath cover.
10. Re-insert dipstick in guide tube.
11. Unclip cover caps.
12. Unscrew bolts (arrows) and remove air cleaner cover.
13. Disconnect breather hose (2) from air cleaner housing.
14. Unplug electrical connector (4) at air mass meter G70.
15. Detach EGR valve N18(Item 3) from air cleaner housing.
16. Move wiring harness going to air cleaner clear (arrow).
17. Loosen hose clip (5) to remove air intake hose.
18. Unscrew bolt (1) and remove air cleaner housing.
19. Disconnect air intake hose from turbocharger (arrows).
20. Detach vacuum hose (1) from vacuum unit for charge pressure control.
21. Detach vacuum hose (2) from vacuum unit for intake manifold flap.
22. Unbolt nuts securing turbocharger to catalytic converter (arrows).
23. Loosen nuts on clamp (arrows).
24. Push the clamp back in order to separate the exhaust system. [Note: Do not bend the flexible joint (de-coupling element) in the exhaust system more than 10°, otherwise it could be damaged.]
25. Disconnect catalytic converter with exhaust pipe from turbocharger. [Note: Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.]
26. Loosen securing bolts of tensioning roller for air conditioner compressor poly V-belt (arrows).
27. Remove poly V-belt.
28. ⚠ Refrigerant circuit of air conditioner must not be opened. — Unbolt air conditioner compressor from bracket.
29. Tie up air conditioner compressor to vehicle, with lines attached.
30. Disconnect air intake hose from turbocharger (bottom) (arrows).
31. Remove bolt (1) from noise insulation cover above drive shaft (right-side).
32. Disengage hook (2) and detach noise insulation.
33. Remove bracket for turbocharger (arrows).
34. Detach oil return pipe at cylinder block (arrow).
35. Drain off coolant .
36. Detach coolant hoses going to expansion tank and to radiator from top coolant pipe.
37. Detach coolant hoses and fuel hoses (1 ... 6).
38. Loosen bolt (arrow).
39. Pull fuel filter upwards out of bracket.
40. Disconnect air intake hose at charge air cooler (arrow).
41. Disconnect vent pipe (1) leading to air cleaner and vacuum line (2) leading to mechanical EGR valve.
42. Loosen hose clip (3) to remove air intake hose at intake connecting pipe.
43. Unplug electrical connectors (2) and (4).
44. Detach vacuum hose (5).
45. Unscrew bolt (1).
46. Remove air pipe (3).
47. Disconnect hose connections (arrows).
48. Detach vacuum line (1).
49. Turn knurled nut (3) for main connector anti-clockwise and unplug connector.
50. Detach fuel hoses (1) and (2).
51. Unbolt bracket for fuel filter (arrows).
52. Detach the coolant hoses at the top coolant pipe.
53. Unscrew nut (arrow).
54. Detach coolant pipe (1).
55. Detach electrical connectors at glow plugs.
56. Unbolt oil supply pipe at oil filter bracket (arrow).
57. Detach coolant hoses (1) and (4) at rear of cylinder head.
58. Unplug electrical connector (3).
59. Unscrew wiring harness clamp (2). [Note: Illustration shows engine removed.]
60. Remove toothed belt: vehicles with hydraulically damped tensioning roller , vehicles with friction-damped tensioning roller .

Other AUDI procedures

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• Checking suction-jet pump – Audi A6 C5
• Testing air mass meter -G70
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• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures