Cylinder Head Assembly: Service and Repair

Cylinder Head

Special tools, testers and auxiliary items required

• Drip Tray for VAS 6100 (VAS 6208)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Spring Type Clip Pliers (VAS 6499)

• Polydrive Bit and Drive Socket (T10070)

• Ignition Coil Puller (T40039)

• Silicone Sealant (D 174 003 A2)

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• Make sure there is enough clearance to moving or hot components to prevent damage to the lines.

Removing

- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.

- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover With Air Filter.

- Remove the battery.

- Open the cover - 1 - for the E-box and remove the wire - 2 -.





- Remove the battery trans bolts - arrows - and remove the battery tray from the vehicle.

CAUTION!
Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.

- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Install the transport strap again onto cylinder head in order to better hold the cylinder head during removal.

- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Service and Repair.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

- Secure the camshafts and remove the camshaft sprocket and adjuster. Refer to => [ Valve Timing, Adjusting ] Adjustments.

- Hold the timing chain - A - as shown so it can be routed below the coolant pipe connection - arrow -.





- Remove the 4 front exhaust pipe nuts - 2 - and the suspended mount bolts - 3 -.





- Remove the front exhaust pipe - 1 - from the manifold and tie up firmly to the side. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe With Catalytic Converter.

• The flex joint in the front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.

- Disconnect the connector for the Heated Oxygen Sensor (HO2S) (G39) at the bulkhead.

- Remove the wire bracket bolts - arrows - from the Secondary Air Injection (AIR) valve.





- Remove the cylinder head bolts in the sequence specified.





• If the bolt - 2 - cannot be removed with a magnet, loosen the bolts for the (T40070) one turn. Slide the (T40070) forward and to the right and tighten the bolts again.

• A second technician is required to remove and install the cylinder head.

- Carefully remove cylinder head.

Installing

• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

• 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.

• Replace cylinder head bolts.

- Stuff clean cloths into the cylinders and chain compartment so that no dirt or abrasive powder can penetrate between the cylinder wall and piston and into chain compartment.

- 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).

- Carefully remove metal particles, emery remains and cloths.

- Cut the tube nozzle at the front mark (nozzle diameter approximately 1 mm).





Note shelf life date.

- Apply a bead of sealant - 1 - (front and rear) onto the clean sealing surfaces as illustrated.





• The sealant bead must be 2.0 to 2.5 mm thick.

- Install the new cylinder head gasket - 2 -.

- Note the centering pins - arrows - in the cylinder block.





- Apply a bead of sealant - 3 - (rear only), as illustrated, on the cylinder head seal.

• The sealant bead must be 2.0 to 2.5 mm thick.

• The cylinder head must be installed within 5 minutes of being applied with sealant.

- Install the cylinder head.

- Guide the timing chain over the coolant pipe connection.

- Install the cylinder head bolts and tighten them hand tight.

- Tighten the cylinder head bolts - 1 through 12 - in the sequence shown as follows:









- Then tighten bolts - 13 - to 10 Nm.

- Wipe off any sealant, which has leaked out.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

• Remove the (T40069) from the rear of the cylinder block and install the locking bolt.

• Replace and fill coolant. Refer to => [ Draining and Filling ] Draining and Filling.

• Install the battery.