Cylinder Head
Cylinder Head
=> [ Cylinder Head Gasket, Preparing for Assembly ]
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Drip Tray (V.A.G 1306)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Spring Type Clip Pliers (VAS 5024A)
• Puller for Ignition Coil (T10095 A)
• Lifting Tackle (3033)
• Shop Crane (VAS 6100)
• Sealant (D 176 501 A1)
Requirements
The engine must be no more than warm to the touch.
Removing
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
- Check if a coded radio is installed. If so, obtain the anti-theft code beforehand.
Disconnect the battery Ground (GND) cable with the ignition turned off.
- Remove the air filter and intake tube. Refer to => [ Air Filter Housing Overview ] Service and Repair.
- Remove the noise insulation.
- Remove the front bumper cover.
- Bring the lock carrier into the service position. Radiator Support
The fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.
- Disconnect fuel supply line - 1 - and catch any escaping fuel with a cloth.
• Press in the securing ring to disengage the fuel line.
• The vacuum line (green) for the Leak Detection Pump (LDP) (V144) must also be disconnected.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Unclip fuel lines at cylinder head cover.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Remove the heat shield over exhaust manifolds.
• Mark the connector assignment to the component before disconnecting the connectors.
- Disconnect connectors from Camshaft Position (CMP) Sensor (G40) - 1 - and Camshaft Position (CMP) Sensor 2 (G163) - 2 -.
- Disconnect the connectors - 3 and 4 -.
- Remove the front exhaust pipe from the exhaust manifolds. Refer to => [ Exhaust Manifold, Front Exhaust Pipes with Catalytic Converters Overview ] Exhaust Manifold, Front Exhaust Pipes with Catalytic Converters Overview.
- Disconnect the 2-pin connector from the Engine Coolant Temperature (ECT) sensor (G62) - arrow -.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the thermostat housing. Refer to => [ Coolant Thermostat Housing Overview ] Coolant Thermostat Housing Overview.
- Remove the combination valve from the cylinder head.
- Remove the coolant hose from the cylinder head to heater core.
- Disconnect the engine wiring harness connector and combination valve pressure hose from the cylinder head.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.
The camshaft lobes - A - for cylinder 1 must face each other.
- Remove the chain tensioner - arrow - for the camshaft timing chain.
- Remove the camshaft front cover bolts - arrows - and the cover.
• Counter hold the camshaft on the recesses - arrow - using a 32 mm open end wrench. (T10068 A) must not be installed when tightening or loosening the camshaft adjuster bolt.
- Remove the exhaust camshaft adjuster.
- Remove the guide rail bolts - arrows - and remove the guide rail - 1 -.
- Place the camshaft timing chain to the side.
- Loosen and remove the cylinder head bolts in the sequence specified starting from the outside working toward the inside.
- Install the (3033) as follows and carefully lift the cylinder head using the (VAS 6100).
Vibration damper side: - 3 - Flywheel side: - 11 -
• The lifting tackle items marked 1 through 12 face toward the flywheel side.
• Threaded spindles are set in length according to necessity.
- Carefully lift cylinder head off.
- Insert clean cloths into the cylinders so that no dirt or abrasive powder can get between the cylinder walls and pistons.
- Do not allow dirt or abrasive powder to get into coolant either.
- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
Installing
- Carefully remove any metal particles, emery remains and the cloths.
If the piston for No. 1 cylinder is not at TDC:
- Adjust the crankshaft at the vibration damper bolt in the direction of engine rotation to the TDC cylinder 1 marking - arrow -. Have a second technician guide the camshaft timing chain by hand when doing this.
• Only remove the new cylinder head gasket from its packing immediately before installing.
• Handle the new gasket with extreme care. Damaging will lead to leaks.
- Apply a 2 mm thick bead of sealant (D 176 501 A1) as shown - arrows - onto the partition of the cylinder block/sealing flange.
- Immediately place new cylinder head gasket on. The text (part number) must be visible.
- Fill both 3 mm holes in the cylinder head gasket with some sealant (D 176 501 A1).
- Ensure the alignment sleeves in the cylinder block bores 12 and 20 are inserted and the cylinder head gasket is secured.
- Position the camshafts in cylinder head to TDC No. 1 cylinder.
- It must be possible to install the (T10068 A) into both camshaft grooves.
- Install the cylinder head, install new cylinder head bolts and tighten them by hand.
• The longer cylinder head bolts must be installed in the middle holes of the cylinder head.
- Tighten the cylinder head bolts in the sequence specified, starting from the inside and working toward the outside, as follows:
- Pre-tighten all the bolts to 30 Nm.
- Then tighten all the bolts to 50 Nm.
- Tighten all the bolts an additional 90° (1/4) turn.
- Afterwards, tighten all the bolts again an additional 90° (1/4) turn.
The rest of the installation is basically a reverse of the removal sequence.
• Ensure the O-ring for sealing the oil passage and the seal in the cover are installed.
- Install the camshaft adjustor with timing chain. Refer to => [ Camshaft Adjuster with Camshaft Timing Chain, Installing ] Camshaft Adjuster with Camshaft Timing Chain, Installing.
- Install the cylinder head cover and intake manifold. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
• There is no requirement to tighten the cylinder head bolts after repairs.
Cylinder Head Gasket, Preparing for Assembly
Special tools, testers and auxiliary items required
• Sealant (D 176 501 A1)
If Only the Camshaft Front Cover was Removed
- Clean old sealing compound from the 3 mm holes in the cylinder head gasket - arrows -.
- Fill the 3 mm holes the in the cylinder head gasket using sealant (D 176 501 A1) and apply sealant (D 176 501 A1) to the sealing surfaces on the cover.
- Install the camshaft front cover immediately.
If the Cylinder Head Gasket was Replaced
- Apply a 2 mm bead of sealant (D 176 501 A1) - arrows - as shown on the cylinder block/sealing flange.
- Immediately place new cylinder head gasket on. The text (part number) must be visible.
- Fill both 3 mm holes in the cylinder head gasket with sealant (D 176 501 A1).