Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip Tray for VAS 6100 (VAS 6208)
• Shop Crane (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)
• Sealant (D 176 501 A1)
• Locking Fluid (D 197 300 A2)
Requirements
• The engine must be no more than warm to touch.
Removing
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Make sure the wires have enough clearance to all moving or hot components.
• To perform this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand.
• Any 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 (V.A.G 1698) for storage.
- Disconnect the battery ground (GND) cable with the ignition turned off.
- Remove the noise insulation.
- Remove the air filter housing. Refer to => [ Air Filter Housing Overview ] One Piece Intake Manifold.
CAUTION!
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 ] Draining and Filling.
- Observe the safety precautions before performing additional repair work. Refer to => [ Safety Precautions ] Fuel Supply.
- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
Release the high side pressure. Refer to => [ High Side Pressure, Releasing ] High Side Pressure, Releasing.
CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Carefully disconnect the connection to reduce the pressure.
- Disconnect fuel line and seal it so that no dirt can enter the fuel supply system.
With a One Piece Intake Manifold
- Remove the intake manifold. Refer to => [ Intake Manifold ] One Piece Intake Manifold.
With a Two Piece Intake Manifold
- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Two Piece Intake Manifold.
- Remove the lower intake manifold. Refer to => [ Lower Intake Manifold, with Fuel Rail ] Two Piece Intake Manifold.
Continuation for All
- Remove the heat shield and the intake manifold support from the cylinder head.
- Remove the front exhaust pipes from the exhaust manifolds.
- Remove the high pressure pump. Refer to => [ High Pressure Pump ] One Piece Intake Manifold.
- Remove the pump plunger - item 17 -=> [ Pump Plunger ] Service and Repair.
- Disconnect the following connectors.
1 - Camshaft Position (CMP) Sensor (G40)
2 - Camshaft Adjustment Valve 1 (N205)
3 - CMP sensor 2 (G163)
4 - Camshaft Adjustment Valve 1 (Exhaust) (N318)
- Disconnect all remaining electrical wires required from the cylinder head and set aside.
- Disconnect the coolant hose from the connecting piece - item 13 -=> [ Connecting Piece ] Cylinder Head Overview to the heater core.
- Remove the upper and lower coolant pipes from the cylinder head cover.
- Remove the vacuum pump, if present. Refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.
- Remove the 3 bolts - 1 through 3 - for the connecting piece.
- Remove the cylinder head cover.
- Rotate the crankshaft in engine rotation direction to the Top Dead Center (TDC) mark - arrow - for cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Remove the camshaft timing chain tensioner - arrow -.
Without a Mechanical Vacuum Pump
- Remove both bolts - 1 - from the sealing flange first and then remove the other bolts - arrows - from the timing chain cover.
With a Mechanical Vacuum Pump
- Remove both bolts - 1 - from the sealing flange first and then remove the other bolts - arrows - from the timing chain cover.
Continuation for All
• Counter hold the camshaft with a 27 mm open end wrench on the recesses - arrow -. (T10068 A) must not be installed when tightening or loosening the camshaft adjuster bolt.
- Remove the bolts - 1 and 2 - and then remove the bolts for the guide rail - 3 -.
- Remove camshaft adjuster.
- Using a screwdriver at the cylinder head - 1 -, pry the bearing shaft - 3 - forward slightly and pull it out in the - direction of the arrow -.
- Remove the drive pinion for the high pressure pump - 2 -.
- Loosen and remove the cylinder head bolts in the specified sequence starting from the outside working toward the inside.
- Remove the 4 bolts - 1 - for the control housing - 2 - and pull down the control housing in the - direction of the arrow - from the camshafts.
- Cover the camshafts - arrows - with clean paper strips and wrap the ends with adhesive tape.
- Install the (3033) as shown and carefully lift the cylinder head using (VAS 6100).
Vibration damper side: position 3
Flywheel side: Position 11
• The (3033) items marked 1 through 12 face toward the flywheel side.
• 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 the 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 threaded bores for the cylinder head bolts.
- Check the cylinder head for warping. Refer to => [ Cylinder Head, Checking
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, using the vibration damper bolt, in engine rotation direction to the TDC mark - arrow - for cylinder 1. Have a second technician guide the camshaft timing chain by hand when doing this.
- Make sure that the alignment bushings are inserted in bore 12 and 20 in the cylinder block.
- Apply a 2 mm bead of sealant (D 176 501 A1) as shown - arrows - on the cylinder block/sealing flange joint.
• Only remove the new cylinder head gasket from its packing 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 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 (T10068 A) into both camshaft grooves.
- Install the cylinder head.
- Apply locking fluid (D 197 300 A2) to each cylinder head bolt- 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 the cylinder head.
- Tighten the cylinder head bolts in the specified sequence, starting from the inside and working toward the outside, as follows:
1 - Tighten the bolts to 15 Nm
2 - Tighten the bolts to 30 Nm
3 - Tighten the bolts an additional 90° (1/4) turn, using a ratchet.
4 - Tighten the bolts an additional 90° (1/4) turn, using a ratchet.
The rest of the installation is basically a reverse of the removal sequence.
- Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster With Timing Chain, Installing.
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
With a One Piece Intake Manifold
- Install the intake manifold. Refer to => [ Intake Manifold ] One Piece Intake Manifold.
With a Two Piece Intake Manifold
- Instal the lower intake manifold. Refer to => [ Lower Intake Manifold, with Fuel Rail ] Two Piece Intake Manifold.
- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Two Piece Intake Manifold.
Continuation for All
Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
• There is no requirement to tighten the cylinder head bolts after repairs.