Cylinder Head Overview
Cylinder Head Overview
• Replace the cylinder head bolts.
• Always replace self-locking nuts, bolts which have been tightened to a torque angle, as well as gaskets and O-rings.
• The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head.
• When replacing the cylinder head or cylinder head gasket, the coolant must be completely replaced.
1 Cylinder Head Gasket
• Always replace.
• Note the installed position: The replacement part number must be visible from the intake side.
2 Bolt
• 25 Nm
3 Transport Strap
4 Bolt
• Always replace.
• Follow the sequence when loosening, refer to => [ Cylinder Head Bolt Loosening ].
• Tightening sequence and specification, refer to => [ Cylinder Head Bolt Tightening Sequence and Specification ].
5 Cylinder Head
• Check for distortion, refer to => [ Checking the Cylinder Head for Distortion ].
• Removing and installing, refer to => [ Cylinder Head ] Cylinder Head.
• Checking compression, refer to => [ Compression, Checking ] Testing and Inspection.
6 Bolt
• Always replace.
• With a washer.
• Follow the sequence when loosening, refer to => [ Cylinder Head Bolt Loosening ].
• Tightening sequence and specification, refer to => [ Cylinder Head Bolt Tightening Sequence and Specification ].
7 O-ring
• Always replace.
• Lubricate with engine oil.
8 Plug
• 5 Nm
• With a ball head for the engine cover.
9 Cap
• With a gasket.
10 O-ring
• No replacement part available.
11 Plug
• Always replace.
• Lubricate the O-ring with engine oil.
12 Bracket
13 Bolt
• 9 Nm
14 Heat Shield
15 Bolt
• 20 Nm
16 Bolt
• 20 Nm
17 to the Intake Manifold/Turbocharger
18 Ventilation Pipe
19 O-ring
• No replacement part available.
20 Gasket
• No replacement part available.
21 Engine Cover
22 Bolt
• Tightening sequence, refer to => [ Crankcase Ventilation Bolt Tightening Sequence and Specification ].
23 Crankcase Ventilation
• Observe the sequence for tightening, refer to => [ Crankcase Ventilation Bolt Tightening Sequence and Specification ].
24 to the Intake Manifold
25 Gasket
• No replacement part available.
26 Gasket
• Replace if damaged.
27 Vacuum Pump
• Removing and installing, refer to => [ Vacuum Pump ] Vacuum Pump.
28 Bolts (M6 x 70)
• 9 Nm
29 Bolt
• 9 Nm
• Only available for engine code CBFA.
30 Secondary Air Injection Solenoid Valve (N112)
• Only available for engine code CBFA.
31 Gasket
• Always replace.
• Only available for engine code CBFA.
32 Retaining Plate
33 Bolt
• 9 Nm
34 Connecting Piece
35 O-ring
• Always replace.
• Lubricate with coolant.
36 Bolt
• 25 Nm
37 Transport Strap
38 Bolt
• 9 Nm
39 Camshaft Position Sensor (G40)
• With a O-ring.
• Lubricate the O-ring with engine oil before installing.
40 Partition Plate
Crankcase Ventilation Bolt Tightening Sequence and Specification
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
Procedure
- Tighten the crankcase ventilation bolts in sequence - 1 through 10 - to 11 Nm.
Cylinder Head Bolt Loosening
Procedure
- Remove the bolts - arrows -.
- Loosen the cylinder head bolts in sequence - 1 through 5 -.
Cylinder Head Bolt Tightening Sequence and Specification
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
Procedure
- Tighten the new cylinder head bolts in 3 passes in sequence - 1 through 5 - Using a TORX(R) bit as follows:
- Tighten the new bolts - 1 through 5 - to 40 Nm.
- Tighten the bolts an additional 90° (1/4) turn.
- Tighten the bolts an additional 90° (1/4) turn.
- Then, tighten the new bolts - arrows - to 8 Nm.
- Then, tighten the bolts - arrows - an additional 90° (1/4) turn.
• There is no requirement to tighten the cylinder head bolts after repairs.
Checking the Cylinder Head for Distortion
Special tools, testers and auxiliary items required
• Straight Edge 500 mm (VAS 6075)
• Feeler Gauge
Procedure
- Check the cylinder head at several locations for distortion using the straight edge 500 mm (VAS 6075) and a feeler gauge.
• Max. permissible distortion: 0.05 mm