Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip tray (V.A.G 1306) or ( VAS 6208)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• Vacuum pump (V.A.G 1390)
• Hand vacuum pump reservoir (V.A.G 1390/1)
• Bracket (T10014)
• Additional hooks (10 - 222 A/2)
Removing
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
- First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
- Disconnect battery Ground (GND) cable with the ignition switched off.
- Remove the engine cover and, if present, remove the upper engine noise insulation => [ Engine, Removing ] Engine, Removing.
- Remove the outer plenum chamber cover and plenum chamber end plate.
- Remove the air filter housing and the intake hose.
- Drain coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Remove the front exhaust pipe => [ Exhaust System Components ] [1][2]Exhaust System Components.
CAUTION!
• The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
• In addition, the fuel system is under pressure! Before opening the system, place cloths around the connection area and release pressure by carefully loosening the connection!
• Wear protective goggles and protective gloves when working on the fuel system!
- Extract the fuel from the tandem pump => [ Tandem Pump ] Tandem Pump.
- Remove the connectors for the glow plugs, the fuel temperature sensor, the pump injector unit (central wiring harness) and coolant temperature.
- Disconnect the fuel hoses and the coolant hose to the lines on the cylinder head - arrows -.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Disconnect the coolant hose - 1 - and the connector - 2 - from the connection.
- Disconnect the hose from the vacuum reservoir.
- Disconnect the right quick coupling on the heat exchanger (from exhaust gas return cooler).
- Disconnect the hose connections - 1 - on the non-return valve and - 3 - leading to the vacuum reservoir.
- Remove the connection - 2 - from the brake booster.
- Disconnect the vacuum hoses at the connection points for the bypass flap (EGR cooler), the intake manifold change-over and the turbocharger.
- Disconnect the connector - 1 -.
- Remove the connecting hose - 7 -.
- Unclip the vacuum hose - 5 - from the rear charge air pipe - 6 -.
- Disconnect the connecting hose on the rear charge air pipe - 6 - and remove it.
- Disconnect the oil return line - 2 - from the connection on the cylinder block.
- Remove the bolts - 3 - and - 4 - and remove the bracket.
- Remove the oil supply line on the oil filter bracket - arrow - and also on the coolant pipe.
- Disconnect the oil supply line on the turbocharger and on the exhaust manifold - arrows - and move the line to the side.
- Toothed belt, removing => [ Toothed Belt ] Toothed Belt.
• Both lifting eye for the engine support bridge are located on the cylinder head. Therefore an additional bracket is mounted on the cylinder block. The engine can be mounted with the spindle - A -.
• Attach the spindle - B - on the cylinder head.
- Then, turn the crankshaft back slightly.
- Remove hub for camshaft sprocket => [ Camshaft ] Service and Repair.
- Remove the toothed belt tensioning roller.
- Remove the coolant pump and the idler roller.
- Remove the camshaft position sensor.
- Remove rear toothed belt guard.
- Fasten the engine bracket (T10014 ) into the threaded hole of the cylinder block in the area of the coolant pump as illustrated.
- With the second spindle - A - and the additional hook (10 - 222 A/2) slightly lift the engine until the spindle - B - is unloaded.
- Unhook the spindle - B - from the lifting eye - 1 - and push it to the side.
- Remove cylinder head cover => [ Cylinder Head Cover ] Service and Repair.
- Follow sequence for loosening cylinder head bolts.
- With a second technician, remove the cylinder head.
Installing
• Always replace cylinder head bolts.
• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.
• Carefully remove all grinding and sanding residue.
• Blow out the threaded holes for the cylinder head bolts thoroughly - to prevent oil from squirting out, place a cloth over each hole.
• Only unpack new cylinder head gasket immediately prior to installation.
• Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.
• Charge pressure hoses and pipes as well as their connections must be free of oil and grease before reinstallation.
- Before installing cylinder head, position crankshaft to TDC marking.
- Turn back crankshaft in opposite direction of engine rotation direction until all pistons stand almost evenly below TDC.
- Observe cylinder head gasket identification.
• Part number = arrow 1
• Control code = arrow 2 (ignore this!)
• Holes = arrow 3
• If the cylinder head gasket or the cylinder head was replaced, select the new cylinder head gasket according the number of holes in the old gasket.
• If parts of the crankshaft were replaced, then the new cylinder head gasket must be selected by measuring the piston position in TDC => [ Piston Position, Checking at TDC ] Piston Position, Checking at TDC.
- Set cylinder head gasket in place.
• Pay close attention to centering bushings - arrows - in cylinder block.
• Pay attention to installation position of cylinder head gasket, marking " oben" (top) or part number must face toward cylinder head.
- Install the cylinder head, insert the new cylinder head bolts and tighten them by hand.
- Tighten cylinder head in sequence indicated, in four stages as follows:
• Tighten the bolts to 40 Nm.
• Tighten the bolts to 60 Nm.
• Then, tighten the bolts 90° (1/4 turn) further.
• Then, tighten the bolts 90° (1/4 turn) further.
• There is no requirement to retighten the cylinder head bolts after repairs.
- After securing the cylinder head and the hub, rotate the camshaft so that cylinder 1 cams point upward - arrows -.
Further installation is performed in reverse order.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
- When installing the oil supply line to the turbocharger, always observe the tightening specification for the threaded connections => [ Oil Supply Line to Turbocharger Assembly Overview ] Oil Supply Line to Turbocharger Assembly Overview.
- Before installing the toothed belt, set the crankshaft to TDC by turning in engine running direction and secure it with the crankshaft stop (T10050).
- Connect battery.
- Perform vehicle system test using => Vehicle Diagnosis, Testing and Information System (VAS 5051) "Guided Fault Finding".
- End vehicle system test, this will automatically erase DTC entries which occurred during the assembly.
Observe safety precautions that apply to road tests.
- Perform test drive.
- After that perform vehicle system test anew and repair any occurring malfunctions.