Removing cylinder head - vehicles with small engine support — AUDI

🧭 Before you start

Remove the particulate filter, battery, air cleaner and the hoses, lines and wiring around the head. Support the engine on the bracket, remove the engine mounting and engine support, set TDC and lock the hub and crankshaft sprocket. Release the tensioner, take off the toothed belt, remove the camshaft sprocket, hub, Hall sender and cylinder head cover, then loosen the head bolts in sequence and lift the head off with a second mechanic.

Fits: Audi A3 (8P, 2003–2012)

• Opens: fuel
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: puller

Don't miss

• Let fuel cool before opening lines; it can reach 100 °C. Wear gloves and goggles.
• Plug all open pipes and connections immediately with clean bungs from VAS 6122.
• Turn the engine only at the crankshaft and only clockwise when setting TDC.
• Mark the toothed belt direction of rotation before taking it off.
• Loosen the cylinder head bolts in the prescribed sequence, never at random.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 95 workshop diagrams for AZV

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

📋 Procedure

1. Remove particulate filter .
2. Remove cover (1) over battery; to do so, press release tab (arrow).
3. ⚠ Observe notes on procedure for disconnecting the battery 27. — With ignition switched off, disconnect battery earth cable (arrow).
4. ⚠ Hot steam or hot coolant can escape when coolant expansion tank is opened; cover filler cap with cloth and open carefully. — Open filler cap on coolant expansion tank.
5. Remove front left wheel.

6. Remove noise insulation (left-side) (fasteners 1 ... 3).
7. Place drip tray for workshop hoistVAS 6208 under engine.
8. Lift retaining clip (arrow) and disconnect coolant hose from radiator.
9. Remove air intake hose (left-side) by lifting retaining clips (arrows) slightly.
10. Remove bolt (arrow) for air intake pipe (left-side).
11. Unscrew nut (1) and remove bracket with wiring from stud.
12. Unclip bracket from wiring harness.
13. Pull cover off air duct (release clips on sides) (arrows).
14. Release clips on left and right (arrow A) and unclip air duct at bottom (2).
15. Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers (3).
16. Detach air pipe (1) from air duct (bottom) (arrow B).
17. Unplug electrical connector (1) at air mass meter G70.
18. Detach vent hose (3) and air hose (2).
19. Unscrew bolt (4) and remove air cleaner housing.
20. Disconnect coolant hose at bottom of engine oil cooler (arrow) and drain off remaining coolant.
21. Remove battery 27.
22. Remove battery tray (arrows).
23. Remove coolant hose between engine and radiator (arrows).
24. Detach crankcase breather hose (2).
25. Move vent hose (4) and vacuum hoses (1) clear at air intake hose.
26. Remove bolt (3).
27. Swing air hose to rear and detach from turbocharger.
28. Detach securing clip (3) for gear selector cable from gearbox selector lever (1) and pull cable off pin (arrow).
29. Detach securing clip (4) for gate selector cable from relay lever (2) and pull cable off pin (arrow).
30. Pull locking device forwards onto stop (arrow 1) and lock by turning anti-clockwise (arrow 2).
31. Press gate relay lever towards front (arrow 3).
32. Remove cable support bracket (arrows) from gearbox and place to one side (selector cables remain fitted).
33. Unclip wiring clip (1).
34. Remove bolts (2) and (3).
35. Detach air pipe (left-side) from turbocharger by lifting retaining clip (4) slightly.
36. Remove air pipe from engine compartment downwards.
37. ⚠ In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear safety goggles. — Disconnect fuel supply hose (2) and fuel return hose (1) from fuel lines.
38. Detach coolant hose (3).
39. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122.
40. Pull release tabs and disconnect fuel supply line (3) and fuel return line (2).
41. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122.
42. Detach coolant hose (1) at coolant expansion tank.
43. Disconnect fuel pipe (press release tab).
44. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122.
45. Move fuel pipe clear.
46. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122.
47. Pull fuel filter upwards out of bracket (arrow) (hoses remain attached).
48. Unscrew bracket (3) for fuel filter.
49. Unscrew bolt at filler neck (2) for washer fluid reservoir.
50. Unplug electrical connector at coolant expansion tank.
51. Unscrew coolant expansion tank (1) and move clear to one side (hoses remain attached).
52. Unplug electrical connector (2) for exhaust gas temperature sender 1G235.
53. Unplug electrical connector at exhaust gas recirculation cooler change-over valve N345(arrow).
54. Set aside wiring harness leading to body.
55. Detach vacuum hose (2) from vacuum unit for charge pressure control.
56. Detach vacuum hose (3) from line going to vacuum unit for change-over flap for exhaust gas recirculation.
57. Disconnect vacuum line from tandem pump.
58. Unclip exhaust gas recirculation cooler change-over valve N345 from bracket.
59. Move exhaust gas recirculation cooler change-over valve N345 clear to one side (vacuum hoses remain attached).
60. Detach oil supply hose (1) from turbocharger.

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