Valve Cover: Service and Repair
Cylinder head cover, removing and installing
Special tools, equipment, test and inspection devices; required accessories
- T1 0029 Spark plug connector tool
- VAG 1331 Torque wrench (5-50 Nm) or equivalent
- VAG 1921 Hose clip pliers
Removing
Note: The ground strap must be disconnected for this procedure. Check to see if a coded radio is installed. If that is the case, you must first obtain the anti-theft code.
- With ignition off, disconnect battery ground strap.
- During installation you must reinstall at same locations all tie straps that were loosened or cut during removal.
- Remove spark plug connector with installation tool T10029 and unclip ignition lines.
- Remove engine cover.
- Disconnect connector from heating resistor (N79).
- Remove inlet hose between air flow sensor (G70) and throttle control unit (J338).
- Disconnect connector -1- from throttle control unit -2.
- Unscrew ground connection at throttle control unit (J338).
- Open and close balancing reservoir sealing cover to allow pressure to escape from cooling system.
- Remove coolant hoses -1- and -2 from throttle control unit and plug hose ends.
- Unclip fuel lines at cylinder head cover.
- Disconnect vacuum connectors arrows-.
- Unclip secondary air pump inlet line and all other lines out of brackets at top half of intake manifold.
- Unscrew dipstick duct at top half of intake manifold.
- Now unscrew two intake manifold support screws.
- Remove vacuum hose at intake manifold switching vacuum actuator.
- Disconnect flow hose -1- (with white marking) and return hose -2- (with blue marking) and catch leaking fuel with a clean rag.
Note: In order to do this, press the tabs at the hose couplings together.
WARNING: The fuel system is pressurized. Before opening the system, plane a clean rag around the connection. Then reduce pressure by carefully and slowly loosening the connection.
- Plug lines so that dirt cannot enter fuel system.
- Remove middle, left and right damping pans.
- Put lock carrier into service position, please refer to: Vehicle /Body and Frame /Radiator support/ Service and repair.
[1][2]Procedures
Vehicles with air conditioning
- Remove V-ribbed drive belt.
- Remove A/C compressor.
- Unscrew refrigerant line retainer clamp(s).
WARNING: Do not open the A/C system refrigerant circuit.
Notes:
- Opening the refrigerant circuit can be done only in shops which have available properly trained personnel as well as all of the necessary tools and equipment.
- To avoid damage to the condenser, coolant lines and hoses, make sure that the lines and hoses are not being overstretched, crimped or bent.
Continued for all vehicles
- Remove combination valve.
- Unscrew upper intake manifold from lower intake manifold.
- Remove upper intake manifold and place it on a suitable surface so that vacuum actuator will not be damaged.
Note: Plug the intake ducts in the lower intake manifold or cylinder head with a clean rag.
- Remove cylinder head cover.
Installing
The installation takes place in the reverse order.
Notes:
- If damaged or leaking, replace cylinder head cover.
- First, screw the upper intake manifold to the lower intake manifold, then tighten both manifold support screws.
- Make sure the fuel hoses are firmly connected.
- If necessary, refill coolant.
- Check DTC memory.
- Adjust basic settings.
- Check readiness code.
- If error memory was erased or engine control unit was disconnected from positive continuous voltage feed, regenerate readiness code.
Tightening torque
Cylinder head cover to cylinder head 10 Nm
Upper intake manifold to lower intake manifold 25 Nm
Upper intake manifold to support right and left 25 Nm
Upper intake manifold to support at cylinder head 25 Nm