Cylinder Head Cover, Removing and Installing Audi TT 8N

Removing

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

1. With ignition switched off, disconnect ground cable (arrow) at battery in rear compartment under floor covering.

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

Scheme 148

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).
2. Pull out oil dipstick.

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 reinstalled, it can be damaged.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Unscrew upper securing bolt -2- for Generator.

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove center sound insulation fasteners -1...3-.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts (arrows) and remove power steering pump from bracket.
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- still attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Unscrew bracket -2- for coolant hose.
4. Unscrew bracket -3- for air filter for secondary air pump.

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Remove lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

1. Disconnect electrical connector -1- for air conditioning compressor clutch.

1. Unscrew bolt (arrow) for air conditioning compressor.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (2nd technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

1. Remove lower securing bolt -1- for Generator.
2. Remove Generator from bracket for ancillary units (electrical wires remain connected).

1. Unscrew clamp -3-.
2. Unscrew wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

Scheme 149

1. Remove bolt -3- and pull out guide tube for oil dipstick -2-.
2. Remove bolt -4- and disconnect vacuum reservoir from manifold.
3. Move vacuum reservoir to side (hoses still attached).

1. Remove bolt (arrow) at bracket for coolant pump for After-run coolant pump -V51-.
2. Remove bolts -1...5- and take off bracket for ancillary units.

Scheme 150

1. Remove bolts (arrows) at front of intake manifold.

Scheme 151

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

Scheme 152

1. Attach puller T10095A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.

1. Remove body brace -1- (arrows).

Scheme 153

1. Move electrical wire (arrow) clear.
2. Loosen hose clamps -1- and -2- and remove air hose between air cleaner housing and Throttle valve control module -J338-.

Scheme 154

1. Disconnect electrical connectors -2- and -3-.
2. Disconnect crankcase breather hose -1-.

Scheme 155

1. Remove bolts (arrows) for Throttle valve control module -J338- and move it clear to one side (coolant hoses remain attached).

Scheme 156

1. Disconnect vacuum hoses -1...4- at rear of intake manifold.

Note. The other hoses remain attached on hose bracket.

1. Unbolt hose bracket from intake manifold (arrows).

Scheme 157

1. Remove rear securing bolts (arrows) for intake manifold.

Scheme 158

1. Protect intake manifold from damage with a clean cloth -1-.
2. Swing intake manifold forward (arrow).

Note. Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from falling in.

Scheme 159

1. Disconnect vacuum hose (arrow) at vacuum unit for intake manifold change-over.

Note. Items -1- and -2- are not applicable here.

1. Unbolt brackets for electrical wires at left on cover for timing chains and at right on cylinder head cover.

1. Unscrew cylinder head cover bolts in sequence -11...1-.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace gaskets for the cylinder head cover and securing bolts if damaged. Replace gaskets for the ignition coils if damaged.

1. Tighten cylinder head cover bolts in sequence -1...11-.
2. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(ref-276269-S32732737022008010300000) .
3. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and air conditioning compressor.
4. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install radiator cowl. Refer to «Radiator, removing and installing»(ref-276269-S03116130422008010300000) .
2. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(ref-276269-S35561992282008010300000) .
3. Install power steering pump.

Refer to 48 STEERING

1. Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(ref-276269-S17467268642008010300000) .
2. Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tightening torques

Scheme 160

Overview of intake manifold components

1 - Change-over mechanism

2 - Bushing

3 - O-ring

1. Replace

4 - Panel bolt

5 - Bearing cap

6 - Intake manifold

7 - 20 Nm

8 - 20 Nm

9 - Seal

10 - Connection for crankcase breather

1. With Positive Crankcase Ventilation (PCV) heating element -N79

11 - O-ring

12 - Throttle valve control module -J338

13 - 10 Nm

14 - 20 Nm

15 - Heat shield for exhaust manifold

1. With support for intake manifold

16 - Gasket

1. Replace
2. Insert into manifold

17 - 13 Nm

18 - Panel bolt

19 - Vacuum unit

20 - Vacuum connection

1. To Intake manifold change-over valve -N156

21 - O-ring

1. Replace

22 - Bushing

Removing

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

1. With ignition switched off, disconnect ground cable (arrow) at battery in rear compartment under floor covering.

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).
2. Pull out oil dipstick.

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 reinstalled, it can be damaged.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Unscrew upper securing bolt -2- for Generator.

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove center sound insulation fasteners -1...3-.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts (arrows) and remove power steering pump from bracket.
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- still attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Unscrew bracket -2- for coolant hose.
4. Unscrew bracket -3- for air filter for secondary air pump.

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Remove lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

1. Disconnect electrical connector -1- for air conditioning compressor clutch.

1. Unscrew bolt (arrow) for air conditioning compressor.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (2nd technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

1. Remove lower securing bolt -1- for Generator.
2. Remove Generator from bracket for ancillary units (electrical wires remain connected).

1. Unscrew clamp -3-.
2. Unscrew wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

Scheme 161

1. Remove connector (arrow) for Engine speed (RPM) sensor -G28- from retainer on oil dipstick guide tube.

1. Remove bolt -3- and pull out guide tube for oil dipstick -2-.
2. Remove bolt -4- and disconnect vacuum reservoir from manifold.
3. Move vacuum reservoir to side (hoses still attached).

1. Remove bolt (arrow) at bracket for coolant pump for After-run coolant pump -V51-.
2. Remove bolts -1...5- and take off bracket for ancillary units.

1. Remove bolts (arrows) at front of intake manifold.

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

1. Attach puller T10095A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.

1. Remove body brace -1- (arrows).

1. Move electrical wire (arrow) clear.
2. Loosen hose clamps -1- and -2- and remove air hose between air cleaner housing and Throttle valve control module -J338-.

1. Disconnect electrical connectors -2- and -3-.
2. Disconnect crankcase breather hose -1-.

1. Remove bolts (arrows) for Throttle valve control module -J338- and move it clear to one side (coolant hoses remain attached).

1. Disconnect vacuum hoses -1...4- at rear of intake manifold.

Note. The other hoses remain attached on hose bracket.

1. Unbolt hose bracket from intake manifold (arrows).

1. Remove rear securing bolts (arrows) for intake manifold.

1. Protect intake manifold from damage with a clean cloth -1-.
2. Swing intake manifold forward (arrow).

Note. Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from falling in.

1. Disconnect vacuum hose (arrow) at vacuum unit for intake manifold change-over.

Scheme 162

1. Unclip pipe guide -1- from fuel rail -2-.
2. Disconnect vacuum pipe -3- from fuel pressure regulator.
3. Remove bolts (arrows).
4. Remove fuel rail with fuel injectors from cylinder head and move clear to one side (fuel lines remain attached).

1. Swing intake manifold back to its installed position and remove.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace seals and gaskets.

1. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(ref-276269-S32732737022008010300000) .
2. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and air conditioning compressor.
3. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install radiator cowl. Refer to «Radiator, removing and installing»(ref-276269-S03116130422008010300000) .
2. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(ref-276269-S35561992282008010300000) .
3. Install power steering pump.

Refer to 48 STEERING

1. Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(ref-276269-S17467268642008010300000) .
2. Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tightening torques