Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Torque Wrench (V.A.G 1331)
• SW 17 Socket (V.A.G 1331/6)
• SW 14 Socket, Open Ring (V.A.G 1331/8)
• Multi-Point Socket (T10070)
Removing
• The procedure is primarily shown for the left cylinder head in the following illustration.
• During installation, all cable ties must be re-installed at the same location.
- Drain coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Remove knock sensor electrical connectors - 1 and 2 - from bracket.
- Remove intake manifold.
- Remove left coolant pipe. Refer to => [ Left Coolant Pipe ] Left Coolant Pipe.
- Remove right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe (for right cylinder head).
- Remove left secondary air injection combi-valve. Refer to => [ Secondary Air Injection Left Combination Valve ] Secondary Air Injection Left Combination Valve (for left cylinder head).
- Remove right secondary air injection combi-valve. Refer to => [ Secondary Air Injection Right Combination Valve ] Secondary Air Injection Right Combination Valve.
- Remove rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.
- Remove torque support bracket. Refer to => [ Torque Support Bracket ] Torque Support Bracket (for right cylinder head).
- Remove cylinder head cover. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Remove affected oxygen sensor in front of catalytic converter
- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Remove camshaft timing chains from camshafts. Refer to => [ Camshaft Timing Chains ] Camshaft Timing Chains.
- Remove front muffler. Refer to: Left => [ Left Front Muffler ] Left Front Muffler, right => [ Right Front Muffler ] Right Front Muffler.
Left cylinder head:
- Remove left front wheel.
- Remove front section of left front wheel housing liner.
- Remove bolt - arrow - and pull hydraulic oil pressure pipe forward slightly.
- Remove nuts - 6 to 1 -.
• To improve clarity, the removed engine is shown.
• Both lower securing strips remain installed.
- Remove bolt - 2 - at left catalytic converter bracket.
• Ignore items - 1 and 3 -.
- Remove left exhaust manifold from cylinder head stud bolts and securing strips.
- Lay aside left exhaust manifold with catalytic converter in engine compartment.
Right cylinder head:
- Remove bolts - 2 through 5 - and remove torque support.
• Ignore - 1 -.
- Remove nuts - 6 to 1 -.
• To improve clarity, the removed engine is shown.
• Both lower securing strips remain installed.
- Remove bolt - 2 - at right catalytic converter bracket.
• Ignore - 1 -.
- Remove right exhaust manifold from cylinder head stud bolts and securing strips.
- Lay aside right exhaust manifold with catalytic converter in engine compartment.
Continued for both sides:
- Remove bolts - 1 and 2 - and remove affected chain tensioner.
- Disconnect electrical connectors - arrows - at fuel injectors.
- Remove high pressure line - 2 - from connector on fuel rail.
- Remove high pressure line - 1 - from connector on fuel rail by counterholding at hex head with an open end wrench and loosening union nut.
• Do not change the angles of the high pressure lines.
- Remove locking bolt - arrow -.
- Remove bolts - arrows -.
- Using Socket (T10070), remove cylinder head bolts in - 1 to 10 - sequence.
- Remove bolts and carefully remove cylinder head.
- Lay cylinder head on a soft surface (foam).
Installing
• Tightening specifications. Refer to => [ Cylinder Head Assembly Overview ] Cylinder Head Assembly Overview, => [ Cylinder Head, Tightening Specifications and Sequence ] Cylinder Head Assembly Overview, => [ Camshaft Timing Chain Assembly Overview ] Camshaft Timing Chain Assembly Overview, => [ Secondary Air Injection System Assembly Overview ] Service and Repair.
CAUTION!
The sealing surfaces could be damaged.
• Carefully remove sealant residue from cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging cylinder block.
• No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.
Risk of leaks in cylinder head seal.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder head is installed, only remove plastic base right before cylinder head is installed to protect open valves.
Risk of damaging valves and piston heads after working on valvetrain.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace bolts which have been tightened to torque.
• Replace self-locking nuts as well as sealing rings and seals.
• If a replacement cylinder head is installed, contact surfaces between bearing elements, roller rocker levers and cam running surfaces must be lubricated before installing cylinder head cover.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be re-installed at the same location.
- Check whether camshafts of both cylinder heads stand in "TDC" position.
• Camshaft Clamp (T40070) must be installed on both cylinder heads and tightened to 25 Nm.
• Crankshaft Holder (3242) must be screwed in.
- Position cylinder head gasket.
• Pay close attention to alignment bushings in cylinder block - arrows -.
• Pay attention to installation position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.
- Install cylinder head.
- Tighten cylinder head bolts => [ Cylinder Head, Tightening Specifications and
Sequence ] Cylinder Head Assembly Overview
• Bolts must not be tightened after repairs.
- Tighten locking bolt - arrow -.
- Check whether camshaft timing chain tensioner guide rail is secured with Locking Pin (T40071).
• If the tensioning element was removed from the chain tensioner, note installation position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.
• Disregard - arrow -.
- Clean chain tensioner oil screen - 2 -.
- Place a new gasket - 3 - onto the rear of the chain tensioner - 1 -.
- Set the chain tensioner in place and install the camshaft timing chain, as shown in the illustration.
- Tighten bolts - 1 and 2 -.
The rest of the installation is in reverse order of removal, note the following:
- Install exhaust manifold. Refer to: Left => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold with Catalytic Converter, right => [ Right Exhaust Manifold with Catalytic Converter ] Right Exhaust Manifold With Catalytic Converter.
- Install torque support and torque support bracket => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- Install front muffler. Refer to: Left => [ Left Front Muffler ] Left Front Muffler, right => [ Right Front Muffler ] Right Front Muffler.
- Install camshaft timing chains => [ Installing ] [1][2]Camshaft Timing Chain.
- Install left and right timing chain covers => [ ] Left and Right Timing Chain Covers.
- Install rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.
- Install combination valve for Secondary Air Injection (AIR) system. Refer to: Left => [ Secondary Air Injection Left Combination Valve ] Secondary Air Injection Left Combination Valve, right => [ Secondary Air Injection Right Combination Valve ] Secondary Air Injection Right Combination Valve.
- Install left coolant pipe. Refer to => [ Left Coolant Pipe ] Left Coolant Pipe.
- Install right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe.
- Install cylinder head cover. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install intake manifold.
- Install headlamps.
- Install front bumper cover.
- Check headlamp adjustment.
- To tighten SW 14 union nut at fuel rail, use Torque Wrench (V.A.G 1331) with Socket Insert AF 14, Open Ring (V.A.G 1331/8).
- To tighten SW 17 union nut at fuel rail, use the Torque Wrench (V.A.G 1331) with SW 17 Socket (V.A.G 1331/6).
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Removal and Replacement.
- Change engine oil.
- Change coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.