Cylinder Heads

Cylinder Heads


Because of the threaded connection of the cylinder head through the aluminum cylinder block into the upper bearing bracket, both cylinder heads must always be removed. If the cylinder head bolts are loosened or tightened on one side, the cylinder block is warped.

Special tools, testers and auxiliary items required

• Counterhold Tool Touareg V10 (T10172)

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

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

• Container for Removed Parts (V.A.G 1698)

• Engine Bung Set (VAS 6122)

• Cable Tie

Removing

- Remove the engine and transmission. Refer to => [ Engine, Removing ] Engine, Removing.

- Remove the acoustic covers as well as the cylinder head covers from the cylinder heads.

- Remove the tandem and fuel pumps from the cylinder heads. Refer to => [ Tandem and Fuel Pump ] Tandem and Fuel Pump.

- Set the crankshaft to Top Dead Center (TDC) for cylinder 1. Refer to => [ Valve Timing, Checking ] Adjustments.

- Remove drive gears for camshafts => [ Camshaft Compensation Wheel and Gear ] Service and Repair.

- Remove the bolts (=> [ (Item 8) Bolt ] Cylinder Head Overview) between the control housing and the cylinder head for cylinder banks 1 and 2.

- Loosen and remove the cylinder head bolts in the sequence specified (- arrow - points in driving direction).






- Carefully remove the cylinder heads with assistance of a second mechanic.

• The cylinder heads must be carefully guided to prevent damages.

- Place clean cloths into the cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.

- 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

• Always replace the cylinder head bolts.

• Only unpack new cylinder head gaskets immediately prior to installation.

• Install cylinder head gasket with the same "thickness" index as the one removed.

• Handle the gasket carefully. Damages to the silicone layer and in the areas of the recesses may result in leaks.

- Before installing the cylinder heads, position the crankshaft to TDC for cylinder 1.

- Turn back the crankshaft in the opposite direction of engine rotation until all pistons stand almost evenly below TDC.

- Set the cylinder head gasket in place.

- Position the cylinder head while taking the position of the compensation linkage - arrow - into consideration. Insert the cylinder head bolts with the accompanying washers and tighten by hand.







All cylinder head bolts, except numbers - 1, 2, 17 and 19 - in tightening sequence must be installed with notched washers. Refer to the Parts Catalog.

- Tighten the cylinder head bolts in the sequence shown, in four passes as follows (- arrow - points in driving direction).






1 - Tighten using a Torque Wrench:

1st pass = 30 Nm

2nd pass = 60 Nm

2 - Tighten Further using a Ratchet:

3rd pass = 180° (1/2) additional turn.

4th pass = 180° (1/2) additional turn.

- Install the drive gears for the camshafts. Refer to => [ Camshaft Compensation Wheel and Gear ] Service and Repair.

- Adjust the valve timing. Refer to => [ Valve Timing, Adjusting ] Adjustments.