Hello Folks.
I have a 2001 A6 2.7 and am working on changing the head gaskets. I'm on the passenger-side and discovered that the exhaust manifold bolts are looking damned-near impossible to remove due to space limitations. Has anyone done this job with the engine in the car?? Thanks

 

Go underneath, loosen up the exhaust pipe brackets and 2 nuts on the connector pipe, use 13 mm close end to remove the 2 nuts (tight). At the top, using an allen wrench, remove your kombi valve (3 bolts) and head cap cover (6 bolts), then you can reach the top nut. It's a PITA but once you do it, it's second nature. . . I just replace both sides due to a valve job.

PS . rent torque wrench from AutoZone
Good luck!

 

Awesome. Thanks '02. I did unbolt the kombi valve on the passenger's side and found that it seems to have been repaired at some point, so I am questioning some of the work on the motor. Lots of oil glop all over the frame, subframe etc. The spider-looking oil vent tube assembly was so clogged at the bottom tube that I am considering replacing it. As well, I found some oil inside the closed valves on the #1 cylinder and the next one as well. I'm not sure if that would be valve seals or if it would be the clogged up breather hose assembly or if the turbos are kicking the bucket? I'm wondering if I should just pull the motor and rebuild turbos and do it all since half of the car is apart? She's got high miles (170k), so probably about that time. I did find a coating of oil inside the intake tubes. Probably any oil is more than it should have, but would the bad breather assembly have something to do with that as well?
How big of a job is pulling the motor anyhow? ( Comparatively speaking vs the head gaskets, considering I have no lift, I do have a hoist and stand handy.. Thanks!

 

I'm no expert but pulling the engine will take a lot of work. Just make sure you label everything if you do decide to go for the big project. Google replace audi engine and you will find several tips.


I purchased my '02 ($2K) in July (108K) thinking it was just a 'jumped' timing belt. It was a locked up intake camshaft due to poor oil maintenance - clogged oil ports. I made my own compressor spring jig out of PVC tube and used a 8" clamp. It took the whole day to replace 30 valve seals ($1 ea) but i saved $300 plus parts. Replaced only 3 intake and 2 exhaust valves. Mechanic told me that the lifters didn't need to be replaced although audi recommends it...I hope the mechanic is correct.

i have about 65 hrs in this thing and hope to be finished by this weekend.

Good Luck with yours!

Jim

 

Check out the homemade PVC jig and clamp.

 

I like the creativity. How did you handle the valve keepers though?

 

It was almost like performing surgery. I used a small flat head screwdriver (4") and magnetized the tip with a magnetic. The key is aligning the PCV openings in the right place to get access to proper installation. It got easier after the 2nd and 3rd ones...

I used 2 different PVC sizes - one for intake side and other for exhaust side. The taped washer was due to the smaller OD on the clamp. Overall length on each PVC is 2.5" - took about 10 minutes to make with drill bit and a sharp knife. Be careful with the knife, i had a minor cut to the finger. . .