Cylinder Head Assembly: Service and Repair
Cylinder Head
• The cylinder head can only be removed with the engine removed. Refer to => [ Removing ] Removing.
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Drip Tray (V.A.G 1306)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Spring Type Clip Pliers (VAS 5024 A)
• Puller for Ignition Coil (T10095 A)
• Hose Clip Pliers (VAS 6362)
• Sealant (D 176 501 A1)
• Sealant (D 197 300 A2)
Requirements
• The engine must be removed.
Removing
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 and vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
• All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.
• 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 (V.A.G 1698) for storage.
- Remove the intake manifold, refer to one of the following:
With a one piece intake manifold, refer to => [ Intake Manifold ] Intake Manifold.
With a two piece intake manifold, refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Pull out the high pressure pump plunger - item 17 -=> [ Pump Plunger ] Description and Operation.
- Remove the heat shield and the intake manifold support from the cylinder head.
Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
- Disconnect the connectors from the Camshaft Position (CMP) sensor (G40) - 1 - and CMP sensor 2 (G163) - 2 -.
- Disconnect the connectors from the camshaft adjustment valve 1 (N205) - 3 - and camshaft adjustment valve 1 (exhaust) (N318) - 4 -.
- Disconnect all remaining electrical wires required from cylinder head and set aside.
- Remove the bracket from the cover.
- Remove the vacuum pump, if present. Refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.
- Remove the 3 bolts - 1 through 3 - for the coolant connecting piece.
- Remove the cylinder head cover.
- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.
The camshaft lobes - A - for cylinder 1 must face each other.
- Remove the chain tensioner - arrow -.
- Remove both sealing flange bolts - 1 - first and then remove the other timing chain cover bolts - arrows - from the cover.
• Counter hold the camshaft using a 27 mm open end wrench on the camshaft recesses - arrow -. The (T10068 A) must not be installed when tightening or loosening the camshaft adjuster bolt.
- Loosen the camshaft adjuster bolts - 1 and 2 - and then remove the guide rail bolt - 3 -.
- Remove the camshaft adjuster bolts and adjusters.
- Using a screwdriver at the cylinder head - 1 -, pry the bearing shaft - 3 - forward slightly and pull it out in the - direction of arrow -.
- Remove the drive pinion for the high pressure pump - 2 -.
- Loosen and remove the cylinder head bolts in the sequence specified starting from the outside working toward the inside.
- Remove the 4 control housing bolts - 1 - and remove the control housing - 2 - 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 (3033) as shown and carefully lift off the cylinder head using the (VAS 6100) or (V.A.G 1202 A):
Vibration damper side: position 3
Flywheel side: Position 11
• The (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 cylinders so that no dirt or abrasive powder can get 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").
- Clean all threaded bores for the cylinder head bolts.
- Check the cylinder head for warping, refer to => [ Checking Cylinder Head for Distortion ] Cylinder Head Overview.
Installing
- Carefully remove any metal particles, emery remains and the cloths.
If the piston for cylinder 1 is not at TDC:
- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the TDC cylinder 1 mark - arrow -. Have a second technician guide the camshaft timing chain by hand when doing this.
- Make sure that alignment bushings are inserted in bores 12 and 20 in the cylinder block.
- Place a 2 mm thick bead of sealant (D 176 501 A1) as shown - arrows - onto the partition of the cylinder block/sealing flange.
• 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 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 (T10068 A) into both camshaft grooves.
- Install the cylinder head.
- Apply locking compound (D 197 300 A2) to each cylinder head bolt and the head contact surface - arrow - and install the bolts.
• The locking compound (D 197 300 A2) works as a fine seal over the cylinder head bolt.
• The longer cylinder head bolts must be installed in the middle holes of the cylinder head.
- Tighten the cylinder head bolts in the sequence specified , starting from the inside and working toward the outside, as follows:
- Tighten all the bolts to 15 Nm.
- Tighten all the bolts to 30 Nm.
- Tighten all bolts an additional 180° (1/2) turn.
The rest of the installation is basically a reverse of the removal sequence.
- Install the camshaft adjustors with timing chain. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
- Install the cylinder head cover.
- Install the intake manifold, refer to one of the following:
With a one piece intake manifold, refer to => [ Intake Manifold ] Intake Manifold.
With a two piece intake manifold, refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
• There is no requirement to tighten the cylinder head bolts after repairs.