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)
• Polydrive Bit and Drive Socket (T10070)
Removing
• Removal and installation at left cylinder head is depicted in the following description.
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.
- Remove left primary catalytic converter. Refer to => [ Left Primary Catalytic Converter ] Left Primary Catalytic Converter.
- Remove electrical connectors - 1 - and - 2 - for knock sensor 3 (G198) and knock sensor 4 (G199) from bracket.
- Version 1: Remove air guide hose to Secondary Air Injection (AIR) combi-valves - arrows -.
- Version 2: Remove the vacuum hoses - 1 - and - 3 - from the secondary air injection combination valves.
- Remove the air guide hose - 2 - to the secondary air injection combination valves - arrows -.
- Remove the 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.
- Remove rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.
- Remove camshaft timing chains from camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.
- 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 the bolts - arrows -.
- Loosen the cylinder head bolts with the (T10070) in the sequence - 1 to 10 -.
- Remove cylinder head 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.
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, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be installed at the same location.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.
- Check whether camshafts of both cylinder heads stand in "TDC" position.
• (T40070) must be installed on both cylinder heads and tightened to 25 Nm.
• (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. Refer to => [ 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 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 in reverse order of removal, note the following:
- Install camshaft timing chains => [ Installing ] Camshaft Timing Chain.
- Install left and right timing chain covers => [ Installing ] Left and Right Timing Chain Covers.
- Install rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.
- 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 Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install intake manifold.
- 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 (V.A.G 1331/6).
- Install left primary catalytic converter. Refer to => [ Left Primary Catalytic Converter ] Left Primary Catalytic Converter.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Change engine oil.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.