Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Guide Pins & Handle - 1112 mm (3070)
• Diesel Injection Pump Locking Pin (3359)
• Crankshaft Stop (T10050)
• Camshaft Gear Counter-Holder (T10051)
• Puller (T10052)
• Socket Insert XZN 10 (T10385)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Drip Tray for VAS 6100 (VAS 6208)
• Be sure to obtain the radio anti-theft code because it will be necessary to disconnect the battery ground cable later in the procedure.
• All cable ties which are opened or cut off when removing the cylinder head, must be replaced in the same position when installing the cylinder head.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all wires and lines so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
Removing
- Disconnect the battery Ground (GND) cable with the ignition turned off.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the air filter housing. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.
- Remove the battery and the battery tray.
- Remove the fan shroud and fans. Refer to => [ Fan Shroud with Coolant Fan ] Fan Shroud With Coolant Fan.
- Remove the cold side hose (- item 4 - in the => [ Charge Air System Components Overview ] Service and Repair) from the charge air cooler.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Remove the toothed belt from the camshaft. Refer to => [ Toothed Belt ] Toothed Belt.
- Disconnect the connectors from the EGR vacuum regulator solenoid valve - 1 - and the throttle valve control module - 3 -.
- Remove the bolts for the oil dipstick connection - arrow - and from the EGR connecting pipe - 2 -.
- Remove the bolts - arrows - from the charge air pipe and then disconnect the connector - 1 - from the charge air pressure sensor.
- Open the clamp - 2 -, free up the coolant hose - 3 - and remove the charge air pipe.
- Disconnect the vacuum line from the vacuum pump.
- Remove the engine wiring from the bracket - arrow -.
- Disconnect the vacuum line - arrow -.
- Remove the vacuum line connection - arrow -.
- Remove the bolts for the charge air pipe (- item 15 - in the => [ Charge Air System Components Overview ] Service and Repair) and remove the charge air hose from the turbocharger.
- Remove the vacuum pump from the cylinder head. Refer to => [ Vacuum Pump ] Service and Repair.
- Disconnect the connector - arrow - from the engine coolant temperature sensor and guide the wire out.
Make sure the connecting pipe coupling element does not bend or stretch. Cracks could develop.
- Remove the Exhaust Gas Recirculation (EGR) connecting pipe - item 2 - in the => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
• Use the socket insert XZN 10 (T10385) to remove the bolt at the bottom of the EGR cooler.
- Remove the noise insulation.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.
- Remove the nuts - arrows - for the particulate filter mount - A - from the crankcase.
- Loosen the clamp between the turbocharger and the particulate filter.
- Remove the bolt - arrow - from the bracket on the cylinder head and move the particulate filter to the side.
- Remove the connecting pipe - A - for the EGR cooler.
The exhaust gas temperature sensor 1 covers the upper threaded connector on the turbocharger support and must not be bent. It must be removed.
- Remove the exhaust gas temperature sensor 1 (- 1 -).
- Remove the bolt - arrow - from the support on the turbocharger.
- Remove the coolant hoses at the cylinder head coolant connections.
- Remove the oil supply line bolt - arrow - and then remove the oil supply line.
- Remove the camshaft toothed belt gear and remove the camshaft hub using the puller (T10052).
- Remove the bolt - arrow - for the toothed belt guard.
- Remove the nut for the toothed belt tensioner.
- Disconnect the camshaft position sensor connector - arrow -.
- Follow the sequence when loosening the cylinder head bolts.
• A second technician is needed when removing the cylinder head.
• The toothed belt tensioner is pulled off the stud bolt when lifting the cylinder head out.
• The turbocharger oil return line is pulled out of the support when lifting the cylinder head out.
- Lift the cylinder head first on the transmission side and guide it out of the toothed belt guard. Be careful not to let the toothed belt tensioner fall.
- Lay the cylinder head down so that the oil return line is not bent. Place a wooden block under the exhaust manifold if necessary.
Installing
• Always replace the cylinder head bolts.
• Carefully remove any sealant residue from the cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.
• Thoroughly remove all sanding and grinding residue.
• Only unpack the new cylinder head gasket immediately prior to installation.
• Handle the gasket carefully. Damages to the silicone layer and in the areas of the recesses may result in leaks.
- Before installing the cylinder head, remove the crankshaft stop (T10050) and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under Top Dead Center (TDC).
- Place the cylinder head gasket with the identification upward.
- Slide the guide pins & handle - 1112 mm (3070) into the outer bores on the intake side of the cylinder block in order to center the cylinder head.
• The toothed belt tensioner must be placed on the stud bolt when positioning the cylinder head.
- Install the cylinder head, insert the eight cylinder head bolts and tighten them hand tight.
- Remove the guide pins using the guide pin handle, and then install the remaining cylinder head bolts.
- Tighten the cylinder head bolts in the sequence indicated - 1 through 10 -, in four stages as follows:
1 - Tighten the bolts using a torque wrench:
Step I = 30 Nm
Step II = 50 Nm
2 - Tighten the bolts using a ratchet:
Step III = an additional 90° (1/4) turn
Step IV = an additional 90° (1/4) turn
- Secure the toothed belt guard to the back of the cylinder head.
- Install the hub and the camshaft sprocket.
- Use the diesel injection pump locking pin (3359) to secure the camshaft and high pressure pump.
- Rotate the crankshaft in engine rotation direction and secure it using the crankshaft stop (T10050).
- Install the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.
Further installation is in the reverse order of removal. Note the following:
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Fill the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.
- Perform a road test and check the Diagnostic Trouble Code (DTC) memory. Refer to the vehicle diagnostic tester.