Cylinder Head
Cylinder Head
• The cylinder head can only be removed with the engine removed. Refer to => [ Engine, Removing ] Engine, Removing.
Special tools, testers and auxiliary items required
• Drip Tray for VAS 6100 (VAS 6208)
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Spring Type Clip Pliers (VAS 6499)
• Puller for Ignition Coil (T10095 A)
• Camshaft Bar (T10068 A)
• Lifting Tackle (3033)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Silicone Adhesive Sealant (D 176 501 A1)
• Liquid Locking Fluid (D 197 300 A2)
Requirements
• The engine must be removed.
Removing
Note the following whenever working inside the engine compartment due to limited space:
• Route all lines and wires in their original locations.
• 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 container for removed parts (V.A.G 1698) for storage.
- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Remove the high pressure pump. Refer to => [ High Pressure Pump ] High Pressure Pump.
- Pull out the cam follower - item 17 - in the => [ Valvetrain Overview ] Service and Repair.
- Remove the heat shield and the intake manifold support bolts from the cylinder head.
- Disconnect the following harness connectors.
1 - Camshaft position sensor
2 - Camshaft adjustment valve 1
3 - Camshaft position sensor 2
4 - Exhaust camshaft adjustment valve 1
- Disconnect all remaining electrical wires from the cylinder head and set aside.
- Remove the bracket from the timing chain cover.
- Remove three bolts - 1 through 3 - for the adapter to the water connection.
- Remove the cylinder head cover.
- Rotate the crankshaft using the counterhold tool (T10172) in engine rotation direction to the Top Dead Center (TDC) mark - arrow -.
The camshaft lobes - A - for cylinder 1 must face each other.
- Remove the vacuum pump. Refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.
- Remove both bolts - 1 - from the sealing flange and then remove the cover bolts - arrows -.
- Remove chain tensioner - arrow -.
• Counter hold the camshaft using a 27 mm open end wrench on the camshaft recesses - arrow -. The camshaft bar (T10068 A) must not be installed when tightening or loosening the camshaft adjuster bolt.
- Remove the camshaft adjusters bolts - 1 and 2 - and then remove the bolt for the guide rail - 3 -.
• The timing chain is held by the sealing flange and the oil pump sprocket. The timing chain cannot slip.
- Remove the camshaft adjusters from the camshafts.
- Remove the timing chain from the high pressure pump sprocket.
- Remove the four bolts - arrows - from the control housing and pull the control housing off of the camshafts.
- Cover the camshafts - arrows - with clean paper strips and wrap the ends with adhesive tape.
- Loosen and remove the cylinder head bolts in the specified sequence - 1 through 20 - starting from the outside working toward the inside.
- Install the lifting tackle (3033) as shown and carefully lift off the cylinder head using the workshop crane (VAS 6100) or (V.A.G 1202 A) :
Vibration damper side: Position 3
Flywheel side: Position 11
• The lifting tackle (3033) items marked 1 through 12 face toward the flywheel side.
• The 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 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").
- Clean all the threaded holes for the cylinder head bolts.
- Check the cylinder head for warping. Refer to => [ Checking the 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 in engine rotation direction to the TDC mark - arrow - for cylinder 1 while a second technician guides the camshaft timing chain by hand.
- Make sure that alignment sleeves are inserted in bores 12 and 20 in the cylinder block.
- Place a 2 mm (0.08 inch) thick bead of silicone adhesive 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 silicone adhesive 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 camshaft bar (T10068 A) into both camshaft grooves.
- Now, the cylinder head can be installed.
- Apply liquid locking compound (D 197 300 A2) to each cylinder head bolt in the head contact surface area - arrow - and install the bolts.
• The locking fluid works as a fine seal over the cylinder head bolt.
• The longer cylinder head bolts must be installed in the middle holes of cylinder head.
- Tighten the cylinder head bolts in the specified sequence - 1 through 20 -, starting from the inside and working toward the outside, as follows:
1 - Tighten all the bolts to 15 Nm
2 - Tighten all the bolts to 30 Nm
3 - Tighten all the bolts an additional 90° (1/4) turn
4 - Tighten all the bolts an additional 90° (1/4) turn
- Lubricate the seals for the camshafts and install the control housing. The timing chain must be placed over the camshaft adjuster valves.
- Secure the high pressure pump sprocket position using the adjustment tool (T10363). The mark - A - on the high pressure pump sprocket must be at the top.
- Install the timing chain on the high pressure pump sprocket so that it is "taut" and then install the glide rail bolt - arrow -.
The rest of the installation is basically a reverse of the removal sequence.
- Camshaft adjuster, installing. Refer to => [ Installing ] Camshaft Adjuster.
- Install the cylinder head cover and the intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
• There is no requirement to retighten the cylinder head bolts after the repair is complete.