Removal and installation the cylinder head (diesel engine 1.9-I-TDI) (Audi A6 C5)

This section contains only the operations related to the 110 hp engine. Special instructions for the 115/130 hp engines are given at the end of the section. Operations related to all engines are given in the section describing the 1.8-I petrol engines (125/150 hp).

Remove the engine casing. To do this, remove the two plugs, unscrew the two nuts and remove the casing. On 115/130 hp engines, the casing is screwed on with three nuts.

Remove the timing belt.

Disconnect the wires from the switches and glow plugs.

Clean the connection points of the pipes to the fuel injectors and the high-pressure fuel pump. Unscrew the union nuts and remove the fuel pipes. Close the holes with suitable plugs.

Remove the glow plugs and fuel injectors from the cylinder head.

Use paint to mark the position of the crankshaft pulley, for which make a mark on the pulley and opposite mark on the cylinder block. Then turn the crankshaft 90° (clockwise or counterclockwise), so that none of the pistons are at TDC. Before installing the timing belt, the crankshaft must be set back to the TDC position of the piston of the first cylinder.

To unscrew the cylinder head mounting bolts, use the appropriate socket wrench (for example, HAZET 990 Sig-12). In the reverse order to that shown in Figure 2.42, unscrew the cylinder head mounting bolts.



The cylinder head of a diesel engine must not be subjected to mechanical treatment.



To properly install the cylinder head and cylinder head gasket, screw the AUDI-3070/9 or HAZET 2570-09 guide bolts into the outermost hole in the cylinder block, intended for the cylinder head mounting bolts. If there are no guide bolts, you can make them yourself, for which you need to use two old cylinder head mounting bolts. Cut off the heads from the bolts and cut a slot for a screwdriver instead. After installing the cylinder head, use a screwdriver to unscrew the guide bolts (see fig. 2.40).



If new pistons are installed on the engine, the piston protrusion from the cylinder block must be measured and a new cylinder head gasket must be used.

Depending on the amount of piston protrusion, it is necessary to select the thickness of the new cylinder head gasket. The gasket has markings made in the form of embossed numbers and notches (see fig. 2.41).



Install the cylinder head, being careful not to damage the exhaust manifold heat shield.



Install and hand tighten eight new cylinder head bolts and washers.

Use a screwdriver to unscrew the two guide bolts and screw in two new cylinder head mounting bolts in their place.

Gradually tighten the cylinder head mounting bolts in several stages in the sequence shown in Fig. 2.42.

Tightening torques for cylinder head bolts are the same as for 1.8-I engines (125/ 150 hp).

The tightening torques for the cylinder head bolts of the 1.9-I-TDI engine are as follows:

Step 1 - Tighten to 40 Nm;
Step 2 - Tighten to 60 Nm;
Step 3 - Turn to 90°;
Step 4: Turn it to a 90° angle.

Check the fuel pump injection timing.

Diesel engines 115/130 hp. Unscrew the timing belt pulley from the bushing and hold the bushing on the camshaft. To do this, use the AUDI T10051 and T10052 tools.

Unscrew the timing belt tensioner. Unscrew the stud using two nuts.

Unscrew the cylinder head cover fastening nuts in the reverse order shown in Figure 2.43.



Tighten the cylinder head cover fastening nuts in sequence from 1 to 13 (Fig. 2.43). Tightening torque 10 Nm.

Before installing the cylinder head cover gasket, lubricate the transitions (including on the opposite side) from bearing caps to cylinder head with VW/AUDI-AMV174 004 01.



Tighten the cylinder head mounting bolts in the same sequence as on the 1.8-I petrol engine.