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)
• Commercially available XZN M12 socket, minimum 140 mm
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.
- Twist spindles of support elements at left and right at subframe completely downward.
- Remove Tapered Mounting Pin (VAS 6131/10-2) from Scissor Lift Table (VAS 6131 A).
- Remove subframe to the side.
- Remove the exhaust system tract. Refer to: Left => [ Left Exhaust System Tract ] Left Exhaust System Tract, right => [ Right Exhaust System Tract ] Right Exhaust System Tract.
- Remove front power steering pressure line bracket from cylinder head - arrow -.
- Remove front secondary air injection connecting piece from cylinder head - arrows -.
- Remove intake manifold.
- Remove camshaft timing chains from the camshafts. Refer to => [ Camshaft Timing Chains ] Camshaft Timing Chains.
- Remove bolts - 1 - and - 2 - and remove right 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. 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 - 1 to 12 - sequence and remove them.
- 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. Damage in silicon layer and recessed area lead to leakage.
• 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.
• When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.
- Check whether camshafts of both cylinder heads stand in "TDC" position.
• The Camshaft Clamp (T40070) must be installed on both cylinder heads and tightened to 25 Nm - arrows -.
• 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 following the shown sequence:
• There is no requirement to retighten the cylinder head bolts after repairs.
- Tighten locking screw - arrow -.
- Check whether camshaft timing chain tensioner guide rail is secured with Locking Pin (T40071).
• 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.
• Disregard - arrow -.
- Clean chain tensioner oil screen - 2 - if necessary.
- 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 performed in reverse order of removal, noting the following:
- Install the camshaft timing chains. Refer to => [ Installing ] Camshaft Timing Chains.
- Install left and right timing chain covers => [ Installing ] Left and Right Timing Chain Covers.
- Install cylinder head cover. Refer to: 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 the exhaust system tract. Refer to: Left => [ Left Exhaust System Tract ] Left Exhaust System Tract, right => [ Right Exhaust System Tract ] Right Exhaust System Tract.
- Change the engine oil after installing the engine.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
Tightening Specifications
