Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip tray (VAG 1306) or drip tray for workshop crane (VAS 6208)
• Torque wrench 5-50 Nm (VAG 1331)
• Torque wrench 40-200 Nm (VAG 1332)
• Spring type clip pliers (VAS 5024A)
• Polydrive bit and drive socket (T10070) or Polydrive key (3452)
• 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 lines of all types (e.g. fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake 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.
Removing
- Drain the cooling system. Refer to--> [ Draining and Filling ] [1][2]Cooling System, 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 bolts - arrows - and remove the battery holder from the vehicle.
CAUTION!
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.
- Remove the intake manifold. Refer to --> [ Intake Manifold ] Intake Manifold.
- Install the transport strap again onto the 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 ] Cylinder Head Cover.
- Secure the camshafts and remove the chain sprockets for the camshafts. Refer to --> [ Valve Timing, Adjusting ] Adjustments.
- Hold the timing chain - A - as shown to be able to lay it under the pipe connection - arrow -.
- Remove the 4 nuts - 2 - and 2 bolts - 3 -.
- Remove the front exhaust pipe - 1 - from the manifold and tie up firmly of 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 degrees, otherwise it may be damaged.
- Disconnect the electrical connector for the Heated Oxygen Sensor (HO2S) at the bulkhead.
- Remove the wire bracket - 3 - at the Secondary Air Injection (AIR) valve or sealing cap (engines without AIR system) and bolts - arrows -.
- Remove the cylinder head bolts in the sequence specified.
• If the bolt - 2 - was not able to be removed using a magnet, loosen the bolts for the (T40070) one rotation, slide the (T40070) toward the front on the right (seen in direction of travel) and tighten the bolts again.
• A second mechanic is required to remove and install the cylinder head.
- Carefully remove the 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 the cylinder head bolts.
- Insert 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 the chain compartment.
- 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).
- Carefully remove any metal particles, emery remains and cloths.
- Cut the tube nozzle at the front marking (diameter of nozzle approximately 1 mm).
Note the shelf life date.
- Apply a bead of sealant - 1 - (front and rear) on 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 alignment pins in the cylinder block - arrows -.
- 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 pipe connection.
- Install the cylinder head bolts and tighten them hand tight.
- Then tighten the cylinder head bolts - 1 to 12 - in the sequence shown as follows:
- Then tighten the 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 cylinder block and install the locking bolt.
• Fill the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
• Install the battery.