Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Tool Insert, AF 17 (V.A.G 1331/6)

• Socket Insert AF14 (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.

- Remove exhaust system tract. Refer to => [ Left Exhaust System Tract ] Left Exhaust System Tract, refer to => [ Right Exhaust System Tract ] Right Exhaust System Tract.

- Remove front secondary air injection connecting piece from cylinder head - arrows -.





- Remove the intake manifold.

- Remove camshaft timing chains from the camshafts. Refer to => [ Camshaft Timing Chain, Removing from Camshafts ] Camshaft Timing Chain, Removing From Camshafts.





- Remove the bolts - 1 - and - 2 - and then remove the left 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 the bolts - arrows -.





- Loosen cylinder head bolts in sequence - 1 to 12 - 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 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.

• It is necessary to replace the coolant and engine oil whenever the cylinder head or the cylinder head gasket are 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 according to the tightening sequence:









• There is no requirement to tighten the cylinder head bolts after repairs.

- Tighten locking bolt - arrow -.





- Make sure the guide rail for the camshaft timing chain tensioner is secured with the locking pin (T40071).





• If the tensioner was removed from the chain tensioner, then pay close attention to the installed position: the hole in the bottom of the housing faces the chain tensioner and the piston faces the 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 the bolts - 1 - and - 2 -.

The rest of the installation is in reverse order of removal, note 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 the cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- To tighten SW 14 union nut at fuel rail, use (V.A.G 1331) with (V.A.G 1331/8).





- To tighten SW 17 union nut at fuel rail, use the (V.A.G 1331) with SW 17 socket.





- Install the intake manifold.

- Install exhaust system tract. Refer to => [ Left Exhaust System Tract ] Left Exhaust System Tract, refer to => [ 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