Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Engine sling (2024A)
• Engine support (T10014)
• Assembly tool (T10352)
• Counter holder tool (T10355)
• Locking pin (T40011)
• Ignition coil puller (T40039)
• Torque wrench 5-50 Nm (VAG 1331)
• Torque wrench 40-200 Nm (VAG 1332)
• Shop crane (VAS 6100)
• Engine bung set (VAS 6122)
• Drip tray for VAS 6100 (VAS 6208)
• Polydrive bit and drive socket (T10070)
Removing
• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
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 (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid or vacuum) and electrical wires 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.
- Remove the engine cover. Refer to --> [ Engine Cover ] Engine Cover.
- Remove the air filter. Refer to --> [ Air Filter ] Air Filter.
- Loosen the charge air hose clamp - 2 -.
- Remove the charge air pipe bolt - 4 -.
- Disconnect the charge air pressure sensor electrical connector - arrow - and free up the electrical wire.
CAUTION!
Risk of scalding due to hot steam and hot coolant:
• When the engine is warm the cooling system is under pressure.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the cap for the coolant expansion tank.
- Remove the front exhaust pipe with catalytic converter. Refer to --> [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the noise insulation..
- Remove the right front wheel.
- Remove the right front (rear) wheel housing liner.
- Remove the charge air hose by lifting the clamp - 1 - and loosening the hose clamp - 2 -.
- Seal off the connections on the charge air cooler with clean cloths.
- Place the (VAS 6208) under the engine.
• Collect any leaking coolant in a clean container for disposal or reuse.
- Drain the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Remove the charge air pipe bolt - 1 - and remove the pipe downward.
- Remove the charge air pipe bolts - arrows -.
- Remove the charge air pipe by lifting the clamps - 1 and 2 -.
- Disconnect the turbocharger recalculating valve - 1 - and wastegate bypass regulator valve - 2 - electrical connectors and free up the electrical wire - arrows -.
- Remove the bolts - 1 and 2 - and remove the turbocharger support.
- Remove the banjo bolt - 2 - and move the coolant supply line to the side.
- Remove the bolts - 1 - for the oil return line.
- Remove the bolt - 3 - for the oil supply line.
- Remove the charge air pipe to noise generator. Refer to --> [ Charge Air Pipe to Noise Generator ] Service and Repair.
- Disconnect the electrical connector - 1 - from the camshaft adjustment valve 1.
- Remove the ignition coils with output stages. Refer to --> [ Ignition Coils with Power Output Stages ] Service and Repair, and lay the wiring harness to the side.
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the bolts - arrows -.
- Remove the air guide pipe bolt - arrow -.
- Loosen the hose clamp - 2 - and remove the air guide pipe together with the crankcase ventilation.
CAUTION!
• The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before loosening the connection, place a cloth around the connection. Then release pressure by carefully disconnecting the connection.
- Disconnect the lines on the supply location and catch any fuel coming out with a cloth.
1. Ventilation line (press the circlip to release the line).
2. Vacuum line (press the circlip to release the line).
3. Fuel supply line (pull the circlip upward to release the line).
- Disconnect the coolant hose - arrow - leading to the coolant expansion tank.
- Remove the coolant hoses - arrows - from the coolant pipe.
- Remove the bolt - 4 - and remove the ground wire - 3 -
- Disconnect the vacuum hoses - arrows -.
- Remove the bolts - 1 though 3 - and remove the heat shield together with the coolant pipe.
• Remove the heat shield bolt - 2 - using a 6 mm socket - A -. The socket must be at least 5 cm - B - long. A socket that tapers to 6 mm at the tip is too wide.
- Disconnect the oil supply line from the turbocharger - 4 -.
- Disconnect the electrical connector - 2 - from the fuel pressure regulator valve.
With Engine Code CBFA
- Disconnect the connector - A - and hose - B - from the Secondary Air Injection (AIR) solenoid valve.
- Loosen the coolant pipe by removing the bolts - arrows -.
Continuation for All Engine Codes
- Disconnect the coolant hose from the side connection on the cylinder head.
- Disconnect the electrical connectors - 1 through 4 -.
- Lay the wire - 5 - to the side.
- Disconnect the Evaporative Emission (EVAP) canister vacuum hose - 6 -.
- Disconnect the electrical connector - 1 - and pull the connectors out of the retainer.
- Disconnect the electrical connectors - 2 through 4 -.
- Disconnect the coolant line from the intake manifold by the removing the bolts - arrows -.
- Remove the intake manifold bracket by removing the nut - 1 - and bolt - 2 -.
- Remove the oil filter.
- Disconnect the coolant hoses - arrows - and move them to the side.
- Remove the bolts - arrows - and remove the camshaft adjustment valve 1.
- Remove upper timing chain cover. Refer to --> [ Upper Timing Chain Cover ] Upper Timing Chain Cover.
CAUTION!
The control valve has left hand threads.
- Remove the control valve using the (T10352) in the - direction of arrow -.
- Remove the bolts - arrows - and remove the bearing bracket.
- Rotate the vibration damper to the "OT" position - arrow - using the (T10355):
• The notch on the vibration damper must line up with the arrow on the lower timing chain cover.
- Carefully mark the drive chain/sprockets - arrows - with a waterproof marker. These marks are necessary for the reinstallation.
- Remove the plug - arrow -.
- Lift the chain tensioner locking wedge by inserting a scribe or a suitable screwdriver into the hole in the chain tensioner - arrow direction 1 -.
- In order to tension the chain tensioner, turn the crankshaft in the opposite direction of engine rotation - arrow direction 2 - and secure it using the (T40011).
• The intake camshaft switches in the engine direction of rotation.
- Remove the bolt - 1 - and guide the tensioning rail - 2 - downward.
- Remove the upper guide rail - 3 - by unlocking the latch (located in the center) with a screwdriver and pushing the guide rail forward.
• When the lower timing chain cover is installed, the loose chain on the crankshaft can not jump off.
- Remove the camshaft timing chain from the sprockets.
CAUTION!
Danger of damaging the valves, piston head and lower timing chain cover:
• If the camshaft timing chain was removed form the cylinder head, then the crankshaft may not be turned further.
• Panels are installed on the lower timing chain cover to prevent the chain from falling down. The panels can bend if the crankshaft is rotated when the chain is loose.
- Turn the sealing plugs - arrows - counterclockwise - direction of arrow - 90 degrees and remove.
- Remove the ball head studs - 1 and 2 -.
- Remove the oil fill cap.
- Remove the bolts - arrows -.
- Remove the cylinder head bolts in sequence - 1 through 5 - using the (T10070) until 2 are left.
• To remove the cylinder head bolts, turn the camshaft with a wrench if necessary.
• Make sure all necessary electrical wires are loosened!
• Pay attention to the tensioning and guide rails when lifting the cylinder head.
- Install the (T10014) and each of the two small and large washers, as shown in the illustration.
1. M8 washer, small.
2. M8 washer, large. The outer diameter of the washer must be larger than the hole in the bracket.
3. M8 x 30 bolt.
- Install the (2024A) to the (T10014) and in the front left lifting eye on the cylinder head.
- Install the (VAS 6100) to the (2024A) and gently lift the cylinder head.
- Remove the last 2 cylinder head bolts.
CAUTION!
• Carefully lift the cylinder head until the guide rail for the camshaft timing chain is free.
• The tensioning and guide rails must not be damaged.
- Lay the cylinder head on a soft surface, such as foam.
Installing
Tightening specifications:
• With engine code CCTA, refer to --> [ Cylinder Head Assembly Overview, Engine Code CCTA ] .
• With engine code CBFA, refer to --> [ Cylinder Head Assembly Overview, Engine Code CBFA ] Cylinder Head Assembly Overview, Engine Code CBFA.
CAUTION!
The sealing surfaces could be damaged:
• Carefully remove any sealant residue from the cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging the cylinder block:
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Risk of the cylinder head seal leaking:
• Carefully remove all grinding and sanding residue.
• Only open the new cylinder head gasket immediately prior to installation.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves:
• If a replacement cylinder is installed, only remove the plastic base right before the cylinder head is installed to protect the open valves.
Risk of damaging valves and piston heads after working on valvetrain:
• To ensure the valves do not strike the pistons when starting, carefully rotate the engine at least 2 full revolutions.
• Replace bolts which have been tightened to specifications.
• Replace sealing rings, seals and self locking nuts.
• Note the different sealant for the cylinder head sealing surfaces and bolts.
• Secure all hose connections using hose clamps appropriate for the model type.
• When installing a replacement cylinder head, turn the camshaft to OT and mark the new sprockets exactly the same as the old sprockets -arrows- (note the factory color marking on the sprockets).
• If an exchange cylinder head is installed, all contact surfaces between the bearing elements, roller rocker levers and cam running surfaces of the camshafts must be oiled before installing the cylinder head cover.
• The engine oil and coolant must be changed if the cylinder head or cylinder head gasket are replaced.
- Hang the cylinder head on the (VAS 6100) and position it above the cylinder block.
CAUTION!
• Carefully lower the cylinder head.
• The tensioning and guide rails must not be damaged.
• Pay attention to the alignment pins in the cylinder block - arrows -.
• Observe the cylinder head gasket location, identification: replacement part number must be visible from the intake side.
CAUTION!
When turning the crankshaft, make sure the timing chain cannot damage any other components.
- In the event the crankshaft has been rotated in the meantime: Set the piston of cylinder 1 to Top Dead Center (TDC) and turn crankshaft back again slightly.
- Set the cylinder head in place.
- Install the cylinder head bolts and tighten by hand.
• In order to be able to turn the cylinder head bolts, the intake camshaft must be turned with a wrench.
Cylinder head bolt tightening sequence and specification:
• With engine code CCTA, refer to --> [ Cylinder Head, Bolt Tightening Sequence and Specification ] .
• With engine code CBFA, refer to --> [ Cylinder Head Bolt Tightening Sequence and Specification ] Cylinder Head Assembly Overview, Engine Code CBFA.
• There is no requirement to retighten the cylinder head bolts after repairs.
CAUTION!
When turning the crankshaft, make sure the timing chain cannot damage any other components.
- Rotate the vibration damper to the "OT" position - arrow - using the (T10355):
• The notch on the vibration damper must line up with the arrow on the timing chain lower cover.
• The marked links of the timing chain must be positioned on the markings on the sprockets.
- Install the camshaft timing chain:
• The markings on the drive chain/sprockets - arrows - must align.
- Turn the intake camshaft using the wrench in the - direction of the arrow - and install the timing chain.
Install in reverse order of removal. When doing this, note the following:
- Fill the engine with oil.
- Check the oil level. Refer to --> [ Oil Level, Checking ] Testing and Inspection.
- Replace the coolant. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
CAUTION!
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase all DTC entries which may have occurred during assembly. Refer to "Guided Function".
• If the DTC memory was erased, generate a readiness code.