Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• 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)

• Polydrive Bit and Drive Socket (T10070)

• Ignition Coil Puller (T40039)

• Silicone Sealant (D 174 003 A2)

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.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

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.

- Drain the coolant. Refer to => [ Draining and Filling ] Service and Repair.

- Remove the air filter (engine cover). Refer to => [ Air Filter and Engine Cover ] Air Filter and Engine Cover.

- Remove the intake hose - 4 - between the throttle valve control module (J338) and air filter. To do so, disconnect the hose - 1 -, if present, and the hose - 2 - (compress the securing ring) and remove the spring clamp - 3 -.






- Remove the battery and the battery tray.

- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Install the transport strap to the cylinder head again to hold the cylinder head when removing it.

- Remove the timing chain cover. Refer to => [ Chain Compartment Cover ] Service and Repair.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

- Lock the camshafts and remove the camshaft sprockets. Refer to => [ Valve Timing, Adjusting ] Adjustments.

- Hold the timing chain - A - as shown, to be able to lay it under the adapter - arrow -.






- Remove the 4 front exhaust pipe nuts - 2 - and the exhaust system suspended mount bolts - 3 -.






- Remove the front exhaust pipe - 1 - from the exhaust manifold and tie up firmly to the side => [ Exhaust Pipe with Catalytic Converter ] Service and Repair.

Danger of causing damage to the flex coupling element:

• Do not bend the flex coupling element more than 10°.

• Do not stretch the flex coupling element.

• Do not damage the wire mesh on the flex coupling element.

- Disconnect the connector for the heated oxygen sensor (G39) at the bulkhead.

- Remove the wire bracket bolts - arrows - from the Secondary Air Injection (AIR) valve or sealing caps (engines without AIR) - arrows -.






- Remove the cylinder head bolts in the sequence shown.






• If the bolt - 2 - is not able to be removed using a magnet, loosen the bolts for the camshaft clamp (T40070) one rotation, slide the camshaft clamp (T40070) toward the front right (seen in the 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 holes for the cylinder head bolts.

• 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.

• 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 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 the cloths.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).






Note the shelf life date of the sealant.

- Apply a bead of sealant - 1 - (front and rear) to the clean sealing surfaces as illustrated.






• The sealant bead must be 2 to 2.5 mm thick.

- Install the new cylinder head gasket - 2 -.

- Note the alignment sleeves - arrows - in the cylinder block.






- Apply a bead of sealant - 3 - (rear only), as illustrated, to the cylinder head gasket.






• The sealant bead must be 2 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 adapter (water pipe connection).

- Install the cylinder head bolts and tighten them hand tight.

- Then, tighten the cylinder head bolts - 1 through 12 - in the sequence shown as follows:











- Then, tighten the bolts - 13 - to 10 Nm.

- Wipe off any excess sealant, which has leaked out.

The rest of the installation follows the reverse of the removal procedure. When doing this note the following:

• Remove the locking pin (T40069) from the cylinder block and install the plug.

• Install the battery tray and battery.

• Replace the coolant. Refer to => [ Draining and Filling ] Service and Repair.