Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Ignition Coil Puller (T40039)
• Assembly Tool (T10352) and Assembly Tool (T10352/1)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Engine Bung (VAS 6122)
• Polydrive Bit and Drive Socket (T10070)
• Lever (T40243)
• Camshaft locator (T40271)
• Locking Tool (T40267)
Removing
• During installation, cable ties must be installed at the same location.
• Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the (VAS 6122).
- Remove the engine cover - arrows -.
- Remove the cover for the air guide; to do this, disengage the side clips - arrows -.
- Unclip the lower air guide, to do this, disengage the clips - arrows -.
- Remove both the lower air guide and the air guide hose.
- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).
- Remove the air guide hose - 2 -.
- Remove the bolt - 4 - and the air filter housing.
• Ignore - 3 -.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the connector - arrow - and free up the wire.
• Ignore - 1 and 3 -.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.
- Open the coolant reservoir cap.
- Remove front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the right front wheel.
- Remove the noise insulation.
- Loosen the fasteners - 1, 2 and 3 - and remove the right noise insulation.
Cabriolet
- Remove the frame for the noise insulation.
All
- Remove the air guide pipe - 1 and 2 -.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Remove the bolt - 1 - and remove the air guide pipe downward.
• Ignore - 2, 3 and 4 and the arrow -.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the air guide pipe.
- Disconnect the connectors - 1 and 2 - and free up the wire - arrows -.
- Remove bolts - 1 and 2 - and remove the turbocharger support.
- Remove the banjo bolt - 2 - and move the coolant line to the side.
- Remove the bolts - 1 - on the oil return line.
- Remove the bolt - 3 - on the oil supply line.
• The installation location is shown with the engine removed.
- Press the release buttons, remove the air guide hose - 2 - and move them to the side.
- Remove the air guide pipe bolts - arrows -.
- Lay aside the air guide pipe with the connected crankcase ventilation hose - 1 -. Loosen the hose clamp - 3 - to do this.
- Disconnect the oil supply line from the turbocharger - 1 -.
- Disconnect the electrical connectors - arrows - on the ignition coils.
- Remove the ignition coils with the (T40039).
- Disconnect the crankcase ventilation hoses - 1 and 2 -.
- Remove the bolts - arrows - and remove the crankcase ventilation.
- Remove the vacuum hose from the vacuum pump - 1 - and free it up.
- Remove ground wire - 2 -.
- Disconnect the connector - 3 - and free up the wiring harness.
- Remove the coolant hoses - 4 and 5 -.
Engine Code CBFA
- Disconnect the connector - A - and hose - B - from the Secondary Air Injection (AIR) solenoid valve (N112).
- Loosen the coolant pipe; remove the bolts - arrows -.
All Vehicles
- Remove the coolant hoses on the rear of the cylinder head.
- Disconnect the connectors - 1 through 4 -.
- Free up the electrical cable - 5 -.
- Disconnect the vacuum hose - 6 - leading to the Evaporative Emission (EVAP) filter.
- Disconnect the connectors - 1 - and pull the connectors out of the retainer.
- Disconnect the connectors - 2 through 4 -.
- Remove the vacuum line - 5 -.
- Disconnect the coolant line from the intake manifold, when doing this, remove the bolts - arrows -.
- Remove the intake manifold bracket by removing the mounting nut - 1 - and bolt - 2 -.
- Remove the oil filter.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Risk of contamination to the fuel system.
• Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect fuel supply hose - 2 - by pressing release ring.
- Disconnect the vacuum line - 1 - to the EVAP canister by pressing the release button.
- Remove the coolant hose - 3 -.
- Pull the EVAP canister up out of the bracket - arrow - and place it on the engine.
- Disconnect the coolant hoses - arrows - and free them up.
- Disconnect the connector from the camshaft adjustment valve 1 (N205) - 1 -.
- Remove the bolts - arrows - and then the camshaft adjustment valve 1.
- Remove the bolts - 1 through 5 - and the upper timing chain guard.
The control valve has a left thread.
- Remove the control valve using the (T10352) or (T10352/1) in direction of - arrow - depending on the version.
- Remove the bolts - arrows - and remove the bearing bracket.
- Rotate the vibration damper using the (T10355) into the Top Dead Center (TDC) position.
• The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite one another - arrow -.
• The markings - 1 - on the camshafts must point upward.
- Mark the camshaft timing chain and the cylinder head - arrows - to match the marking on the chain sprockets - 1 - with a waterproof marker.
- In addition, mark the camshaft timing chain to the camshaft timing chain guide rail - 2 - with a permanent marker.
- Remove the plug - arrow -.
- Remove the bolts - arrows -.
- Remove the bolt - arrow -.
Two Different Chain Tensioners may be Installed Depending on the Version
Version 1
- Install the (T40243) - arrows -.
- Insert a scriber or a suitable screwdriver into the opening for the chain tensioner in the direction of the- arrow 1 - to lift up the locking wedge for the chain tensioner, slowly press down the (T40243) and hold it in the direction of the - arrow 2 -.
- Secure the chain tensioner using (T40011).
Version 2
- Install the (T40243) - arrows -.
- Press the chain tensioner locking ring - arrow - together and slowly press and hold the (T40243) in the direction of the - arrow -.
- Secure the chain tensioner with the (T40267).
All
- Remove the (T40243).
- Bolt the (T40271/2) to the cylinder head and push the chain sprocket splines in the direction of the - arrow 2 -. If necessary, turn the intake camshaft with a wrench in the direction of the - arrow 1 -.
- Remove the bolt - 1 - and guide the tensioning rail - 2 - downward.
- Attach the (T40271/1) to the cylinder head.
- Turn the exhaust camshaft with the wrench in the direction of - arrow 1 - and slide the (T40271/1) in the chain sprocket splines in the direction of the - arrow 2 -.
- Remove the upper guide track - 1 - by unlocking the latch with a screwdriver and pushing the guide track forward.
- Remove the camshaft timing chain from chain sprockets.
Risk of damaging valves and piston crowns.
• If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.
- Turn the sealing plug - arrows - counterclockwise 90° in the direction of the - arrow - and remove it.
- Remove the ball head - 1 through 2 -.
- Remove the cap.
- Remove the bolts - arrows -.
- Remove the cylinder head bolts with the (T10070) in the following sequence: - 1 through 5 -.
• Make sure all wires and cables are disconnected.
• Pay attention to the tension and guide tracks when lifting the cylinder head.
- Remove the cylinder head.
- Lay the cylinder head on a soft surface, such as foam.
Installing
• 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.
• 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 valve train.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace the bolts which are being tightened with an additional turn.
• Replace self-locking nuts, sealing rings, seals and O-rings.
• 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 camshafts.
• The hose supports, air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory.
• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.
When using a New Cylinder Head
- Mark the camshaft sprocket to the (T40271/1) and the (T40271/2) - arrow -.
- Turn the intake camshaft with a wrench in the direction of - arrow 1 -, slide the (T40271/2) out of the chain sprocket splines if the direction of - arrow 2 - and bring the camshaft into the rest position.
- Remove the (T40271/2).
- Turn the exhaust camshaft with a wrench in the direction of - arrow 1 -, slide the (T40271/1) out of the chain sprocket splines if the direction of - arrow 2 - and bring the camshaft into the rest position.
- Remove the (T40271/1).
- Transfer the self-made markings from the old camshafts to the new camshafts.
- Attach the (T40271/2) to the cylinder head.
- Turn the intake camshaft in the direction of - arrow 1 - until the markings - 3 - align with the (T40271/2).
- Slide the (T40271/2) into the chain sprocket splines in the direction of - arrow 2 -.
- Attach the (T40271/1) to the cylinder head.
- Turn the exhaust camshaft in the direction of - arrow 1 - until the markings - 3 - align with the (T40271/1).
- Slide the (T40271/1) into the chain sprocket splines in the direction of - arrow 2 -.
All
- Set cylinder head gasket in place.
• Pay attention to centering pins in cylinder block - arrows -.
• Observe cylinder head seal location, identification: The part number must be visible from the intake side.
When rotating the crankshaft, make sure the timing chain cannot damage any other components.
- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
- Set cylinder head in place.
- Insert cylinder head bolts and tighten by hand.
- Cylinder head tightening sequence. Refer to => [ Cylinder Head Tightening Sequence ] Cylinder Head Overview
• There is no requirement to tighten the cylinder head bolts after repairs.
When rotating the crankshaft, make sure the timing chain cannot damage any other components.
- Rotate the vibration damper using the (T10355) into the TDC position - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
- Position the markings on the chain links - arrows - at the chain sprockets - 1 - to install the camshaft timing chain.
- Install the upper glide track - 2 -.
- Turn the exhaust camshaft in the direction of the - arrow 1 -, slide out the (T40271/1) from the chain sprocket splines in the direction of the - arrow 2 - and release the camshaft.
- Remove the (T40271/1).
- Move the tensioning rail - 2 - up and install the bolt - 1 -.
- Turn the intake camshaft in the direction of - arrow 1 -, slide out the camshaft locating tool (T40271/2) from the chain sprocket splines in the direction of - arrow 2 - and release the camshaft.
- Remove the (T40271/2).
- Check the valve timing. The camshaft timing chain and cylinder head - arrows - must align with the markings on the chain sprocket - 1 -.
- The markings for the camshaft timing chain and the camshaft timing chain glide track - 2 - must be opposite one another.
- The notch on the vibration damper must be opposite the marking on the lower section of the timing chain guard - 3 -.
- Mount the bearing bracket and the bolts - arrows - hand-tight.
- Remove the (T40011) or the (T40267) , depending on the version.
- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Install the bolt - arrow -.
- Install the control valve - item 6 - => [ (Item 6) Control Valve ] Camshaft Timing Chain Overview.
- Turn the intake camshaft using the wrench in the direction of the - arrow - and mount the timing chain.
Further assembly is performed in the reverse order of removal, thereby observing the following:
- Install the timing chain guard upper section. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.
- Change engine oil.
- Replace coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.