Cylinder Head
Cylinder Head
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 no more than warm to touch.
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.
• Any cable ties which are opened or cut off when removing, must be replaced in the same position when installing.
• Use the container for removed parts (V.A.G 1698) to store removed parts so that they do not get damaged.
- 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 ] Air Filter Housing Overview.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.
- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
The fuel lines are under pressure.
Danger of personal injury to eyes and skin.
Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.
- Disconnect the fuel supply line - 1 -.
- Plug the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Remove the lower intake manifold and disconnect all connectors. Refer to => [ Lower Intake Manifold, with Fuel Rail ] Lower Intake Manifold, with Fuel Rail.
- Unbolt 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 ] High Pressure Pump.
- Pull out the cam follower.
- Disconnect the following connectors.
1 - Camshaft position (CMP) sensor
2 - Camshaft adjustment valve 1
3 - CMP sensor 2
4 - Exhaust camshaft adjustment valve 1
- Disconnect all remaining electrical wires required from the cylinder head and set aside.
- Remove the coolant hose from the water connection - item 13 - in the => [ Cylinder Head and Cover Overview ] Cylinder Head and Cover Overview.
- Remove the upper and lower coolant pipes from the cover.
- Remove the vacuum pump. Refer to => [ Vacuum Pump ] Vacuum Pump.
- Remove the bolts - 1 through 3 - from the water connection.
- Remove the cylinder head cover.
- Rotate the crankshaft in engine rotation direction to Top Dead Center (TDC) for cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Remove the chain tensioner - arrow -.
- Remove both bolts - 1 - from the sealing flange and then remove all the cover bolts - arrows -.
• Counter hold the camshaft with a 27 mm open end wrench on the camshaft recesses - arrow -. The camshaft bar (T10068 A) must not be installed when loosening the camshaft adjuster bolts.
- Loosen the camshaft adjuster bolts - 1 and 2 - and then remove the guide rail bolt - 3 -.
• The timing chain is held by the sealing flange on the oil pump chain sprocket. The timing chain cannot skip.
- Remove the camshaft adjusters from the camshafts.
- Remove the camshaft timing chain from the high pressure pump sprocket.
- Remove the four bolts - arrows - from the control housing and pull the housing off the camshafts.
- Cover the camshafts - arrows - with strips of paper and tape the ends.
- Loosen the cylinder head bolts working from the outside to the inside in the sequence given - 20 through 1 - and then remove them.
- Install the lifting tackle (3033) as illustrated and carefully lift the cylinder head using the shop crane - load cap - 700-1200 KG (VAS 6100).
Vibration damper side: Position 3
Flywheel side: Position 11
• The lifting tackle (3033) side marked 1 through 12 faces 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 the cylinder walls and pistons.
- Do not allow dirt or abrasive powder to get into the coolant either.
- Carefully clean the sealing surfaces on the cylinder head and cylinder block. 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 distortion. Refer to => [ Checking the Cylinder Head for Distortion ] Cylinder Head and Cover 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 TDC for cylinder 1 - arrow - while a second technician guides the camshaft timing chain by hand.
- Make sure that alignment bushings are inserted in bores 12 and 20 in the cylinder block.
- Apply a 2 mm bead of silicone adhesive sealant (D 176 501 A1) on the joint between the cylinder block/sealing flange as illustrated - arrows -.
• Only unpack a new cylinder head gasket immediately prior to installation.
• Be very careful when handling the new gasket. Damaging will lead to leaks.
- Install the cylinder head gasket immediately. The text (part number) must be visible.
- Fill both 3 mm holes on the gasket with silicone adhesive sealant (D 176 501 A1).
- Rotate the camshafts inside the cylinder head to TDC for cylinder 1.
The camshafts - A - for cylinder 1 must face each other.
- It must be possible to install the camshaft bar (T10068 A) into both camshaft grooves.
- Install the cylinder head.
- Apply liquid locking fluid (D 197 300 A2) to each cylinder head bolt at the head contact surface area - arrow - and insert the bolts.
• The liquid locking fluid works as a fine seal over the cylinder head bolt.
• The longer cylinder head bolts must be inserted in the middle holes of the 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 - Then, tighten all the bolts to 30 Nm.
3 - Tighten all the bolts an additional 90° (1/4) turn using a ratchet.
4 - Tighten all the bolts an additional 90° (1/4) using a ratchet.
- Lubricate the seals on the camshafts and install the control housing. The timing chain must be placed over the camshaft adjuster valves.
- Secure the high pressure pump drive pinion 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 instal the guide rail bolt- arrow -.
Further installation is in the reverse order of removal.
- Install the camshaft adjusters. Refer to => [ Camshaft Adjuster ] Camshaft Adjuster.
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Install the lower intake manifold. Refer to => [ Lower Intake Manifold, with Fuel Rail ] Lower Intake Manifold, with Fuel Rail.
- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Fill with new coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
• There is no requirement to retighten the cylinder head bolts after repairs.