Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Lifting Tackle (3033)
• Shop Crane (VAS 6100)
• Camshaft Bar (T10068 A)
Removing
• Engine installed.
• During installation, cable ties must be installed at the same location.
- Drain coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.
- Remove intake manifold.
- Pull the EVAP cannister - 1 - in the engine compartment together with the connected hoses upward out of the bracket and lay it to the side.
There is a risk of injury because the fuel is under pressure.
• To reduce pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
- Disconnect fuel supply hose - 4 - by pressing release ring.
- Remove coolant hoses - 2 and 3 -.
- Disconnect knock sensor (KS) 1 (G61) electrical sensor - arrow - and free up electrical wiring.
- Remove cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Disconnect electrical connectors - 1 through 6 - on fuel injectors.
- Unclip line router on fuel rail - arrows -.
- Remove coolant hoses - arrows -.
• The illustration shows the coolant hoses on a vehicle with direct shift automatic transmission (DSG).
- Remove coolant thermostat housing. Refer to => [ Coolant Thermostat Housing ] Coolant Thermostat Housing.
- Remove camshaft timing chain from camshafts. Refer to => [ Camshaft Timing Chain ] Camshaft Timing Chain.
- Remove heat shield over exhaust manifold - arrows -.
Risk of damaging decoupling elements.
• Do not bend decoupling element in front exhaust pipe more than 10°.
- Remove nuts - 1 through 6 - and slide front exhaust pipe back slightly from exhaust manifolds.
• Oxygen sensors remain installed.
- Loosen and tighten cylinder head bolts in sequence - 1 to 20 -.
- Re-tightening left front engine lifting eye - arrows -.
• The left engine lifting eye was removed to remove the intake manifold.
- Engage Lifting Tackle (3033) as follows:
• Belt pulley side: Position "3".
• Transmission side: Position "10".
• The Lifting Tackle (3033) items labeled with "1 through 12" face toward the transmission side.
- Carefully raise cylinder head.
Risk of contaminating cylinder wall and piston.
• Place clean cloths in cylinder.
Installing
• Tightening specifications, refer to => [ Cylinder Head - Tightening Specifications and
Tightening Sequence ] Cylinder Head and Cylinder Head Cover 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.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Risk of cylinder head seal leaking.
• 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 torque.
• Replace sealing rings, seals and self-locking nuts.
• If a replacement cylinder 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.
- Position camshafts at "TDC" before cylinder head is installed.
• It must be possible to insert (T10068 A) into both shaft grooves.
- Check again if crankshaft is at "TDC" marking - arrow -.
- Set cylinder head gasket in place.
• Observe the centering pins in cylinder block.
• Observe cylinder head seal location, identification: Part number must be visible from intake side.
- Set cylinder head in place.
- Insert cylinder head bolts and tighten by hand.
• The longer cylinder head bolts must be inserted in the middle holes of cylinder head.
- Tighten cylinder head bolts. Refer to => [ Cylinder Head - Tightening Specifications and
Tightening Sequence ] Cylinder Head and Cylinder Head Cover Assembly Overview.
• Do not tighten cylinder head bolts after repairs.
- Installing exhaust manifold. Refer to => [ Exhaust Manifold ] Exhaust Manifold.
- Install camshaft timing chain => [ Installing (Adjusting valve
timing) ] Camshaft Timing Chain.
- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover
- Install intake manifold.
- Follow measures after connecting battery.
- Change engine oil.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.