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)
• Socket (T10070) or socket XZN M12, minimum 140 mm, commercially available
Removing
• Engine/transmission assembly removed and mounted on Scissor Lift Platform (VAS 6131 A).
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
• The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.
- Remove electrical harness connectors - 1 - and - 4 - from bracket at transmission.
- Disconnect electrical harness connectors.
- Remove heat insulation sleeve on wiring harness and free up individual electrical wires.
- Remove bolt - 1 - at left front exhaust pipe strap.
• Ignore - 2 -.
- Remove nuts - arrows -.
- Remove front exhaust pipe with pre- and main catalytic converters.
- Remove intake manifold.
- Remove the camshaft timing chain from the camshafts: vehicle through 03.2007. Refer to => [ Camshaft Timing Chains, through 03.2007, Removing from Camshaft ] Camshaft Timing Chains, Through 03.2007, Removing From Camshaft, vehicles from 03.2007, refer to => [ Camshaft Timing Chains, from 03.2007, Removing from Camshaft ] Camshaft Timing Chains, From 03.2007, Removing From Camshaft.
- Remove bolts - 1 - and - 2 - and remove right chain tensioner.
• Ensure tensioning piston does not slip out of chain tensioner and fall to the ground.
- 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. To do this, counterhold at hex head with and open-end wrench and loosen the union nut.
• Do not change the angles of the high pressure lines.
- Remove locking bolt - arrow -.
- Remove bolts - arrows -.
- Loosen cylinder head bolts in the sequence - 1 to 10 -.
- Remove cylinder head and place it on a soft surface (foam).
Installing
• Replace cylinder head bolts.
• Replace self-locking nuts and bolts.
• Always replace bolts that are tightened to torque as well as O-rings and gaskets.
• Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
• Carefully remove all grinding and sanding residue.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Only unpack new cylinder head gasket immediately prior to installation.
• Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.
• Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked.
• After installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller rocker levers and cam lubricating surfaces after installing cylinder head.
• Do not remove plastic bases protecting the open valves until immediately before installing cylinder head.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be re-installed at the same location.
• After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.
• After replacing cylinder head or cylinder head seal, coolant and engine oil must be changed.
- 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.
- Insert new cylinder head bolts and tighten by hand.
- Tighten the bolts in 6 steps according to the tightening sequence:
• There is no requirement to retighten the cylinder head bolts after repairs.
- Tighten locking bolt - arrow -.
Vehicles through 03.2007:
- Completely release guide rail on removed camshaft timing chain tensioner - arrow -.
• The chain tensioner piston - 1 - must be driven out completely, thereby releasing the retainer.
• If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.
- Press camshaft timing chain tensioner inward - arrow - as far as stop and secure chain tensioner with Locking Pin ( T40071).
- Clean chain tensioner oil screen - 2 - if necessary.
- Place a new gasket - 3 - onto the rear of the chain tensioner - 1 -.
Vehicles from 03.2007:
- Press left and right camshaft timing chain guide rail inward - arrow - as far as stop and secure chain tensioner with Locking Pin (T40071).
- Clean oil strainer - 2 - in both chain tensioners if necessary.
- Place a new gasket - 3 - onto the rear of the chain tensioner - 1 -.
All Vehicles
- 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 installation is in reverse order of removal, note the following:
- Install the camshaft timing chains. Refer to => [ Installing ] Camshaft Timing Chains, Through 03.2007.
- Install left and right timing chain covers => [ Installing ] Left and Right Timing Chain Covers.
- Install cylinder head cover: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- To tighten union nut (14 mm) at fuel rail use the Torque Wrench (V.A.G 1331) with 14 mm Open End Wrench Socket (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).
- Install intake manifold.
- Install front exhaust pipe with pre- and main catalytic converters. Refer to: Left => [ Left Front Exhaust Pipe with Primary and Main Catalytic Converters ] Left Front Exhaust Pipe With Primary and Main Catalytic Converters; right => [ Right Front Exhaust Pipe with Primary and Main Catalytic Converters ] Right Front Exhaust Pipe With Primary and Main Catalytic Converters.
- Change the engine oil after installing the engine.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
Tightening Specifications
