Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip tray (V.A.G 1306) or drip tray for workshop crane (VAS 6208)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• Diesel extractor (VAS 5226) or hand vacuum pump (VAS 6213) or hand vacuum pump (V.A.G 1390) and
• Hand vacuum pump reservoir (V.A.G 1390/1)
• Bracket (T10014) (only vehicles through 05.05)
• Engine support bridge (10 - 222 A) with adapter (10 - 222 A/13) (only vehicles through 05.05)
• When using an exchanged cylinder head with camshaft installed, the contact surfaces between the lifters and cam lobes must be lubricated before installing the cylinder head cover.
• The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.
• When cylinder head is replaced, all coolant must also be replaced.
• Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the tears have a width of max. 0.5 mm.
• Do not mill the valve seats in the cylinder head; only grinding of the valves is permissible.
• After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).
• 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.
• Always replace gaskets and seals.
• All cable ties which are opened or cut open when removing cylinder head, must be replaced in the same position when installing cylinder head.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
Removing
• Before removing the cylinder head, extract the fuel with the hand vacuum pump and the draining container (V.A.G 1390/1)=> [ Tandem Pump ] Tandem Pump.
- Turn the ignition and all electrical consumers off and remove the ignition key.
- Remove engine cover.
One Piece Engine Cover
Pull the one piece front engine cover - arrows A - upward with a quick jerk and then pull the lower mount - arrow B - forward.
Two Piece Engine Cover
On the two piece engine cover, first pull the outer cover upward with a quick jerk - arrows in the upper illustration -, then pull the inner engine cover upward with a quick jerk - arrows in lower illustration -.
- Remove plenum chamber bulkhead
- Disconnect the connector - 2 - on the Mass Air Flow (MAF) sensor (G70).
- Disconnect the ventilation hose - 1 - and disengage it from the bracket - arrow -.
- Open the spring-type clip- 3 - using spring-type clip pliers (VAS 5024A) and disconnect the intake hose from the Mass Air Flow (MAF) sensor (G70).
- Disconnect the intake manifold - 5 - from the air guide.
- Unfasten bolt - 4 - and remove air filter housing and mass air flow sensor.
- Remove noise insulation
- Drain the coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- For safety reasons, pull the connector - arrow - off the fuel delivery unit.
- Disconnect the fuel supply and return lines, as well as the coolant line on the cylinder head.
- Before removing the cylinder head, extract the fuel with the diesel extractor (VAS 5226) or the hand vacuum pump and the breather reservoir (V.A.G 1390/1) to the tandem pump => [ Tandem Pump ] Tandem Pump.
Fuel Filter Without the Retaining Plate
- Release the clips and remove the fuel filter with the hoses still connected from the retaining plate - arrow -.
Fuel Filter With the Retaining Plate
- Loosen the bolt - 1 - one turn.
- Remove the bolt - 2 - and the nut - 3 -.
- Remove the fuel filter with the hoses still connected.
Continuation for All
- Remove the front exhaust pipe => [ Front Exhaust Pipe ] Service and Repair.
- Remove the turbocharger support and the oil return from the turbocharger.
- Remove the oil supply line and lay the oil supply line off to the side => [ Oil Supply Line ] Oil Supply Line.
• From 06.05 a revised engine mount is being installed, which no longer requires that the engine mount be removed and that the engine be supported "Toothed Belt, Removing and Installing, Tensioning"=> [ Toothed Belt ] Toothed Belt.
- Remove toothed belt => [ Toothed Belt ] Toothed Belt.
- Remove the toothed belt tensioning roller.
- Remove hub for camshaft sprocket => [ Camshaft ] Service and Repair.
- Remove the bolts for the rear toothed belt guard - 2 - and - 4 -.
- Remove the Camshaft Position (CMP) sensor (G40) - 3 -.
- Remove the connecting pipe for exhaust gas recirculation.
- Pull off/disconnect all remaining electrical wires required from cylinder head and set aside.
- Disconnect all connections, coolant lines, vacuum hoses and intake hoses from the cylinder head.
Only Vehicles Through 05.05
• Both lifting eyes for the engine support bridge are located on the cylinder head, for that reason an additional holder to support the engine must be secured on cylinder block.
- Fasten the engine support (T10014) into the threaded bore above the coolant pump to 20 Nm.
- Using spindle - A -, lift engine slightly until spindle - B - is unloaded.
- Unhook the spindle - B - and push it aside.
Continuation for All
- Remove cylinder head cover => [ Cylinder Head Cover ] Service and Repair.
- Follow the sequence when loosening the cylinder head bolts.
- Lift the cylinder head slightly and then remove it from the engine sideways, past the toothed belt guard.
• The cylinder head must be carefully guided to prevent damages.
Installing
• Always replace cylinder head bolts.
• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.
- Before installing cylinder head, position crankshaft to TDC marking.
- Turn the crankshaft in opposite direction of engine rotation until all pistons are positioned almost evenly below TDC.
- Position cylinder head gasket.
• Observe cylinder head gasket identification => [ Identification of Cylinder Head Gasket ] Cylinder Head Assembly Overview
- Set cylinder head in place and tighten all cylinder head bolts hand tight.
- Fasten the cylinder head in four steps according to the indicated tightening sequence, as follows:
1 - Tighten using torque wrench
Step 1 = 35 Nm
Step 2 = 60 Nm
2 - Tighten further using a ratchet
Step 3 = 1/4 turn (90°)
Step 4 = 1/4 turn (90°)
• There is no requirement to retighten the cylinder head bolts after repairs.
Further installation is performed in reverse order. When doing this note the following:
- After fastening the cylinder head turn the camshaft sprocket so that the lobes - arrows - for cylinder 1 point upward equally. Before installing the toothed belt, turn the crankshaft in engine rotation direction to TDC => [ Toothed Belt ] Toothed Belt.
- Install hub for camshaft sprocket => [ Camshaft ] Service and Repair.
- Install toothed belt => [ Toothed Belt ] Toothed Belt.
- Install ribbed belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.
- Install oil supply line => [ Oil Supply Line ] Oil Supply Line.
- Install noise insulation
- Install plenum chamber bulkhead
- Fill with coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Perform a test drive and afterwards check the fault memory => [ Engine Control Module DTC Memory, Checking and Erasing ] Engine Control Module DTC Memory, Checking and Erasing.