Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Retainer (3036)
• Hose Clamps Up to 25 mm Dia. (3094)
• Engine Bung Set (VAS 6122)
• Puller (T10320)
• Crankshaft Holder (3242)
• Adjusting Pin (T40060)
• Sealant, refer to the Parts Catalog
Removing
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Remove the affected camshaft timing chain from the camshaft. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.
- Remove the upper section of the intake manifold.
- Remove the respective cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
Left Cylinder Head
- Remove the upper left coolant pipe. Refer to => [ Left Upper Coolant Pipe, Vehicles Built through 05.10 ] Left Upper Coolant Pipe, Vehicles Built Through 05.10.
- Remove the high pressure pump toothed belt and the belt tensioning roller.
- Loosen the toothed belt drive sprocket bolt - 1 - 2 turns using the (3036).
- Remove the toothed belt drive sprocket using the (T10320).
- Remove the bolts - arrows - and leave the rear toothed belt guard in its installation position.
- Remove the bolt - 2 - for the oil dipstick guide tube.
• Ignore - 1 -.
- Mark the injector high pressure line for re-installing.
- Remove the union nuts - 2 - and - 3 -, free up and remove the high pressure line.
• Ignore - 1, 4 - and - arrows -.
- Remove the T-connector from the coolant hose - arrow -.
- Disconnect the connector - 1 - on the intake flap motor 2 (V275) - 4 -.
• Ignore - 2 and 3 - and - arrows -.
Vehicles Built from 06.10
• Place a cloth underneath to soak up any escaping power steering fluid.
- Clamp off the power steering pump hydraulic hose - 1 - with a (3094).
- Remove the bolts - 2 - and move the hydraulic line to the rear.
- Seal the open lines and connections with clean plugs from the engine bung set (VAS 6122).
All Vehicles
- Loosen the clamp - arrow - and remove the exhaust gas recirculation pipe - 1 -.
Right Cylinder Head
- Remove the right intermediate pipe. Refer to => [ Right Intermediate Pipe ] Right Intermediate Pipe.
- Remove the right upper coolant pipe. Refer to => [ Upper Right Coolant Pipe ] Upper Right Coolant Pipe.
- Remove the bolts - arrows - and the high pressure line protective plate.
- Mark the injector high pressure line for re-installing.
- Remove the union nuts - 1 - and - 4 -, free up and remove the high pressure line.
• Ignore - 2 and 3 -.
- Remove the engine lifting eyelet bolts - 1 - and - 2 -.
- Free up the wiring harness using (80 - 200) - arrow -.
- Loosen the clamp - arrow - and remove the coolant pipe.
- Disconnect the glow plug connectors for cylinders "2" and "3".
- Disconnect the connector - 1 - on the intake flap motor (V157).
• Ignore - arrows -.
- Remove the connector - 2 - (orange) for exhaust gas recirculation (EGR) temperature sensor (G98) from the bracket and disconnect it.
• Ignore - 1 -.
• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the bolts - arrows - and then move the fuel rail to the side with the hoses still attached.
• Ignore - 1 and 2 -.
Continued for Both Sides
- Loosen the cylinder head bolts in the following sequence - 1 through 8 -.
- Remove the bolts and the cylinder head carefully.
Danger of damaging the glow plugs when removing the cylinder head.
• Do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface
Installing
Install in reverse order of removal. Note the following:
• For the correct tightening specifications, refer to => [ Cylinder Head Overview ] Cylinder Head 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 sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
• 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 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 an additional torque.
• Replace self-locking nuts, sealing rings, seals and O-rings.
• It is not permitted to re-work the cylinder heads on TDI engines
• When installing a replacement cylinder head with the camshaft installed, coat the contact surfaces between the hydraulic adjusting elements, the roller rocker levers and cam running surfaces with oil.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model, refer to the Parts Catalog.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.
- Before positioning the cylinder head, adjust the crankshaft and camshafts to "TDC":
• The (3242) must be installed in the "TDC" position for the crankshaft - 1 -.
• The camshafts on both cylinder head must be locked by the (T40060).
• The bolt - arrow - in the (T40060) must be perpendicular to the center axle of the camshaft.
- Note the cylinder head gasket identification:
1. Holes
2. Part number:
• If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.
• If the crankshaft drive is replaced, measure the piston projection in TDC to determine the new cylinder head. Refer to => [ Piston Projection, Measuring at TDC ] Testing and Inspection.
• The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.
- Clean any oil or grease off the sealing surfaces.
• Note the expiration date of the sealing compound.
• Cut the tube nozzle at the front marking (nozzle diameter approximately 5 mm).
• Components that have had sealant applied to them must be bolted within 15 minutes.
Left Cylinder Head
- Apply a bead of sealant - 1 - and - 2 - on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.
- Apply the sealant in the amounts specified.
• a = 7 mm
• b = 7 mm
• c = 7 mm
- Set cylinder head gasket in place.
- Apply sealant beads - 1 - and - 2 - to the clean sealing surfaces as illustrated.
Right Cylinder Head
- Apply a bead of sealant - 1 - and - 2 - on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.
- Apply the sealant in the amounts specified.
• a = 7 mm
• b = 7 mm
• c = 7 mm
- Set cylinder head gasket in place.
- Apply sealant beads - 1 - and - 2 - to the clean sealing surfaces as illustrated.
Continued for Both Sides
• Pay close attention to alignment bushings in cylinder block - arrows -.
• Pay attention to installation position of the cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.
- Set cylinder head in place.
- Insert new cylinder head bolts and tighten by hand.
- Tighten the cylinder head bolts. Refer to => [ Cylinder Head, Tightening Specifications and Sequence ] Cylinder Head Overview.
• There is no requirement to tighten the cylinder head bolts after repairs.
Left Cylinder Head
- Install the exhaust gas recirculation pipe. Refer to => [ Exhaust Gas Recirculation Overview ] Exhaust Gas Recirculation Overview.
- Install oil dipstick guide tube. Refer to => [ Upper Oil Pan Overview ] Upper Oil Pan Overview.
- Installing the upper left coolant pipe. Refer to => [ Left Upper Coolant Pipe, Vehicles Built through 05.10 ] Left Upper Coolant Pipe, Vehicles Built Through 05.10.
- Install the rear toothed belt guard, the toothed belt tensioning roller and the high pressure pump toothed belt.
- Install the hydraulic pipe.
Right Cylinder Head
- Install the fuel rail.
- Install the right upper coolant pipe. Refer to => [ Upper Right Coolant Pipe ] Upper Right Coolant Pipe.
- Install the right intermediate pipe. Refer to => [ Right Intermediate Pipe ] Right Intermediate Pipe.
Continued for Both Sides
- High pressure lines, install.
- Install the cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install the upper section of the intake manifold.
- Install the camshaft timing chains => [ Installing ] Camshaft Timing Chains, Removing From Camshafts.
- Change engine oil.
- Replace coolant => [ Filling ] Procedures.
- Fuel system, performing leak test. Refer to => [ Fuel System, Checking for Leaks ] Fuel System, Checking For Leaks.