Cylinder Head
Cylinder Head
=> [ Cylinder Head Gasket, Preparing for Assembly ]
Special tools, testers and auxiliary items required
• Camshaft bar (T10068A)
• Drip tray (VAG 1306) or drip tray for VAS 6100 (VAS 6208)
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Spring type clip pliers (VAS 5024A)
• Puller for ignition coil (T10095A)
• Lifting tackle (3033)
• Shop crane (VAS 6100)
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 lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires 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.
All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.
- Check whether a coded radio is installed. If necessary, obtain the antitheft code.
With the ignition switched off, disconnect the battery ground cable.
- Remove the air filter and connecting hose. Refer to => [ Air Filter Assembly Overview ] Removal and Replacement.
- Remove the noise insulation.
- Remove the front bumper cover.
- Bring the lock carrier into the service position. Radiator Support
CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.
- Disconnect the fuel supply line - 4 - and catch any leaking fuel with a cloth.
- Disconnect the vent line - 2 - and vacuum line - 3 -.
• Press in the securing ring to disengage the fuel line.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Unclip the fuel lines at the cylinder head cover.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Remove the Secondary Air Injection (AIR) combination valves and intake manifold support from the shield. Refer to => [ Secondary Air Injection System Components Assembly Overview ] Secondary Air Injection System Components Assembly Overview.
• Before disconnecting the harness electrical connectors, mark the allocation to the component.
- Disconnect the electrical connectors from the Camshaft Position (CMP) sensor - 1 - and the CMP sensor 2 - 2 -.
- Disconnect the electrical connectors - 3 and 4 -.
- Remove the front exhaust pipe from the exhaust manifolds. Refer to => [ Exhaust Manifold and Front Exhaust Pipe with Catalytic Converters Assembly Overview ] Exhaust Manifold and Front Exhaust Pipe with Catalytic Converters Assembly Overview.
- Rotate the crankshaft using the vibration damper bolt in the direction of engine rotation to the Top Dead Center (TDC) cylinder 1 marking - arrow -.
- Disconnect the 2 pin electrical connector - arrow - from the Engine Coolant Temperature (ECT) sensor.
- Drain the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the coolant thermostat housing. Refer to => [ Coolant Thermostat Housing Assembly Overview ] Service and Repair.
- Remove the coolant hose below from the cylinder head to heater unit heat exchanger.
- Remove the coolant pipes on the cylinder head and from the auxiliary heater on the cylinder block, if applicable. Refer to => [ Cooling System Assembly Overview, Engine Side ] Cooling System Assembly Overview, Engine Side.
- Disconnect the engine wiring harness electrical connector and the combination valve pressure hose from the cylinder head.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Remove the chain tensioner for the camshaft roller chain - arrow -.
- Remove the timing chain cover bolts - arrows - and the cover.
• Counter hold only with a 32 mm open end wrench on the camshaft - arrow -. The (T10068A) must not be inserted when tightening or loosening the camshaft adjuster bolts.
- Remove the exhaust camshaft adjuster.
- Remove the guide rail bolts - arrows - and the guide rail - 1 -.
- Place the camshaft roller chain aside.
- Loosen and remove the cylinder head bolts in the sequence shown starting from the outside working toward the inside.
- Install the (3033) as follows and carefully lift the cylinder head using the (VAS 6100).
Vibration damper side: - Item 3 - on 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.
- Stuff clean cloths into the cylinder bores 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 coolant either.
- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper below 100 grit).
Installing
- Carefully remove metal particles, emery remains and the cloths.
If the piston for No. 1 cylinder is not at TDC:
- Rotate the crankshaft using the vibration damper bolt in direction of engine rotation to TDC cylinder 1 marking - arrow -, have a second mechanic guide the camshaft roller chain by hand when doing this.
• 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.
- Place a 2 mm thick bead of sealant (D 176 501 ) as shown - arrows - onto the partition of the cylinder block/sealing flange.
- Immediately place the new cylinder head gasket on. The text (replacement part number) must be visible.
- Also fill some more sealant (D 176 501) into both 3 mm bores in the cylinder head seal, which lie on the sealant bead.
- Ensure the alignment pins in the cylinder block bore 12 and 20 are inserted and the cylinder head gasket is secured.
- Position the camshafts in the cylinder head to TDC No. 1 cylinder.
- It must be possible to insert the (T10068A) into both camshaft grooves.
- Install the cylinder head, install new cylinder head bolts and hand tighten.
• The longer cylinder head bolts must be inserted in the middle holes of the cylinder head.
- Tighten the cylinder head bolts in the sequence shown, starting from the inside and working toward the outside, as follows:
- Pre-tighten all the bolts to 30 Nm.
- Tighten all the bolts to 50 Nm.
- Tighten all bolts 90° (1/4) additional turn, using a ratchet.
- Afterwards, tighten all bolts again 90° (1/4) additional turn.
The rest of the assembly is basically a reverse of the removal sequence.
• Ensure the O-ring for sealing the oil channel and the seal in the cover are installed.
- Adjust the valve timing. Refer to => [ Valve Timing, Adjusting ] Adjustments.
- Install the cylinder head cover and intake manifold. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
• There is no requirement to retighten the cylinder head bolts after repairs.
Cylinder Head Gasket, Preparing for Assembly
Special tools, testers and auxiliary items required
• Sealant (D 176 501)
If Only the Timing Chain Cover was Removed
- Clean the old sealing compound from the 3 mm holes in the cylinder head gasket - arrows -.
- Fill the 3 mm holes the in the cylinder head gasket using sealant (D 176 501) and install the sealant (D 176 501) onto the sealing surface on the timing chain cover.
- Install the cover immediately.
If The Cylinder Head Gasket was Replaced
- Place a 2 mm thick sealant bead of sealant (D 176 501) as shown - arrows - onto the partition of the cylinder block/sealing flange.
- Immediately place the new cylinder head gasket on. The text (replacement part number) must be visible.
- Also fill some more sealant (D 176 501) into both 3 mm bores in cylinder head seal, which lie on the sealant bead.