Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip Tray for VAS 6100 (VAS 6208)
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Spring-Type Clip Pliers (VAS 6499)
• Puller for Ignition Coil (T10095 A)
• Camshaft Bar (T10068 A)
• Lifting Tackle (3033)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Silicone Adhesive Sealant (D 176 501 A1)
• Liquid Locking Fluid (D 197 300 A2)
• Container for Removed Parts (V.A.G 1698)
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 all lines and wires in their original locations.
• Ensure sufficient clearance to all moving or hot components.
• To perform this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand.
• Any cable ties which are opened or cut off during the removal, must be replaced in the same position during the installation.
• When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing the engine.
• To prevent damage to the removed components, use the container for removed parts (V.A.G 1698) for storage.
- If a coded radio is installed, obtain the anti-theft code.
- Disconnect the battery ground cable with the ignition turned off.
- Remove the noise insulation.
- Remove the air filter housing. Refer to => [ Air Filter Housing Overview ] Service and Repair.
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
- Observe the safety precautions before performing any additional repair work. Refer to => [ Safety Precautions ] Fuel Supply.
- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
Release the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.
The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully loosening the union nut.
- Disconnect the fuel supply line - 1 - and catch any leaking fuel with a cloth.
• Press the locking ring to release the fuel line.
- Seal the line so that the fuel system is not contaminated by dirt, etc.
- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Remove the high pressure pump. Refer to => [ High Pressure Pump ] High Pressure Pump.
- Remove the cam follower, - item 17 - in => [ Valvetrain Overview ] Service and Repair.
- Remove the lower intake manifold and disconnect all connectors. Refer to => [ Lower Intake Manifold, with Fuel Rail ] Lower Intake Manifold, with Fuel Rail.
- Remove the heat shield and the intake manifold support from the cylinder head.
- Remove the front exhaust pipes from the exhaust manifolds.
- Disconnect the following connectors.
1 - Camshaft position sensor
2 - Camshaft adjustment valve 1
3 - Camshaft position sensor 2
4 - Exhaust camshaft adjustment valve 1
- Disconnect any remaining electrical wires from the cylinder head and set aside.
- Disconnect the coolant hose from the water connection, - item 13 - in => [ Cylinder Head Overview ] Cylinder Head Overview.
- Remove the upper and lower coolant pipes from the cylinder head cover.
- Remove the vacuum pump. Refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.
- Remove the 3 bolts - 1 through 3 - for the water connection.
- Now, remove the cylinder head cover.
- Rotate the crankshaft in engine rotation direction to Top Dead Center (TDC) for cylinder. 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Remove the chain tensioner - arrow -.
- Remove both sealing flange to cover bolts - 1 - first and then remove the cover bolts - arrows -.
• Counter hold the camshaft using a 27 mm open end wrench on the recess - arrow -. The camshaft bar (T10068 A) must not be installed when tightening or loosening the camshaft adjuster bolt.
- Loosen the bolts - 1 and 2 - and then remove the guide rail bolt - 3 -.
- Now, remove the camshaft adjusters.
- Remove the vacuum pump driveshaft - 4 -.
- Now, the high pressure pump drive sprocket - 6 - can be removed.
- Loosen and remove the cylinder head bolts - 1 through 20 - in the specified sequence starting from the outside working toward the inside.
- Remove the four control housing bolts - arrows - and pull the control housing off, in the - direction of the arrow - from the camshafts.
- Cover the camshafts - arrows - with clean paper strips and wrap the ends with adhesive tape.
- Install the lifting tackle (3033) to the cylinder head as illustrated and carefully lift it using the shop crane - load cap = 700-1200 KG (VAS 6100).
Vibration damper side: Position 3
Flywheel side: Position 11
• The lifting tackle (3033) items marked 1 through 12 face toward the flywheel side.
• Threaded spindles are set in length according to necessity.
- Carefully lift the cylinder head off.
- Insert clean cloths into the cylinder bores so that no dirt or abrasive powder can get between the cylinder wall and the piston.
- Do not allow dirt or abrasive powder to get into the 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").
- Clean all threaded bores for the cylinder head bolts.
- Check the cylinder head for warpage. Refer to => [ Checking the Cylinder Head for Distortion ] Cylinder Head Overview.
Installing
- Carefully remove any metal particles, emery remains and the cloths inserted in the bores.
If the piston for cylinder 1 is not at TDC:
- Rotate the crankshaft in engine rotation direction to TDC for cylinder 1, while a second technician guides the camshaft timing chain by hand.
- Make sure that the alignment bushings are inserted in bores 12 and 20 in the cylinder block.
- Apply a 2 mm of silicone adhesive sealant (D 176 501 A1) as shown - arrows - on the cylinder block/sealing flange joint.
• Only remove the new cylinder head gasket from its packaging immediately before installing.
• Handle the new gasket with extreme care. Damaging will lead to leaks.
- Immediately place the new cylinder head gasket on. The text (part number) must be visible.
- Fill both 3 mm holes with some silicone adhesive sealant (D 176 501 A1).
- Position the camshafts in the cylinder head to TDC for cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- It must be possible to install the camshaft bar (T10068 A) into both camshaft grooves.
- Now, the cylinder head can be installed.
- Apply liquid locking fluid (D 197 300 A2) to each cylinder head bolt, under the bolt head - arrow - and install the bolts.
• The liquid locking fluid works as a fine seal under the cylinder head bolt.
• The longer cylinder head bolts must be inserted in the middle holes of the cylinder head.
- Tighten the cylinder head bolts - 1 through 20 - in the specified sequence, starting from the inside and working toward the outside, as follows:
1 - Tighten all the bolts to 15 Nm
2 - Tighten all the bolts to 30 Nm
3 - Tighten all the bolts an additional 90° (1/4) turn
4 - Tighten all the bolts an additional 90° (1/4) turn
- Lubricate the seals on the camshafts and install the control housing. The timing chain must be placed over the camshaft adjustment valves.
- Secure the high pressure pump drive sprocket position using the adjustment tool (T10363). The mark - A - on the high pressure pump drive sprocket must be at the top.
- Install the timing chain on the high pressure pump drive sprocket so that it is "taut" and then instal the guide rail bolt - arrow -.
Further installation is in the reverse order of removal.
- Install the camshaft adjuster with timing chain. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Install the lower intake manifold. Refer to => [ Lower Intake Manifold, with Fuel Rail ] Lower Intake Manifold, with Fuel Rail.
- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Fill with new coolant. Refer to => [ Draining and Filling ] Procedures.
• There is no requirement to retighten the cylinder head bolts after repairs.