Removing and Installing
Cylinder Head, Removing and Installing
Special Tools and Equipment
- T10068 Camshaft Ruler
- VAG1306 Drip Tray
- VAG1331 Torque Wrench (5 to 50 Nm)
- VAG1332 Torque Wrench (40 to 200 Nm)
- VAS5024 Assembly Tool for Spring Type Clamps
- Sealant AMV 188 001 01
Requirements
- Engine must not be hotter than lukewarm.
Removing
Note:
- In the continuing work procedure the battery Ground (GND) strap must be disconnected. Therefore, determine whether a coded radio is installed. If necessary, determine anti-theft coding first.
- Switch ignition off and disconnect Battery Ground (GND) strap.
- All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Remove cylinder head cover.
- Disconnect fuel supply, as well as return line (arrows) (press release button).
- Disconnect 4-pin connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-.
Note:
- Mark connectors for Camshaft Position (CMP) sensors (-G40- and -G163) before disconnecting. Connectors for Positive Crankcase Ventilation (PCV) heating element -N79- and intake manifold change-over valve -N156- must also be marked.
- Disconnect harness connectors from Camshaft Position (CMP) sensor -G40- and -G163- -1- and -2-.
- Unclip harness connector from valve -1- for camshaft adjustment -N205- and valve -2- for camshaft adjustment -N208- -4-.
- Disconnect 10-pin harness connector of fuel injectors.
- Move wiring harness clear.
- Disconnect/unlatch all remaining essential electrical wires at cylinder head and set aside.
- Disconnect vacuum lines at cylinder head and set aside.
- Now remove thermostat housing, Refer to Cooling system
- Adjust crankshaft using securing bolt of harmonic balancer in direction of engine rotation to TDC cyl. 1 marking (arrow):
- Mark camshaft roller chain before removing (e.g. using paint, mark with an arrow in direction of rotation).
Note:
- Do not mark chain using punch, notch or similar.
- Remove chain tensioner (arrow) for camshaft roller chain.
- Remove securing bolts (arrows) from cover piece and remove it.
Note:
- Bracket -1- and -2- must be removed first.
- Unbolt front exhaust pipe from exhaust manifold.
- Now check adjustment of valve timing.
With a proper TDC position cyl. 1 a groove can be seen on the chain sprockets of the intermediate shaft (arrow).
Note:
- This condition is only reached at every 2nd TDC position.
If the groove cannot be seen:
- Turn crankshaft one more rotation in direction of engine rotation.
Note:
- When rotating crankshaft, instead of the chain tensioner, the tensioning track must be pressed against the camshaft roller chain by hand.
- It must be possible to insert T10068 camshaft ruler into both shaft grooves.
Note:
- If the camshaft ruler still cannot be inserted, turn crankshaft in direction of engine rotation until approximately 5 mm above the TDC position cyl. 1 (limited via tolerances of drive chains).
- Markings -A- and -B- on the camshaft adjusters must match the notches (arrows) of control housing -C-.
- The milled tooth -1- or -2- from camshaft adjuster also points to the notch of control housing -C-.
Note:
- Only counter-hold at camshaft using spanner wrench (32 mm) (arrow). T10063 must not be inserted when tightening or loosening camshaft adjuster.
- Remove camshaft adjuster together with camshaft roller chain from exhaust camshaft.
- Remove bolts (arrows) for slide track -1-.
- Remove camshaft roller chain from camshaft adjuster and place chain on side.
- Loosen and unscrew cylinder head bolts in specified sequence.
Note:
- Use 3452 polydrive key for polydrive cylinder head bolts.
- Carefully remove cylinder head.
Note:
- Stuff clean cloths into cylinders so that no dirt or abrasive powder can get between cylinder wall and piston.
Installing
- Do not allow dirt or abrasive powder to get into coolant either.
- Carefully clean sealing surfaces of cylinder head and cylinder block. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
- Thoroughly remove all sanding and grinding residue and remove cloths.
If piston of cyl. 1 is not in TDC position:
- Adjust crankshaft at securing bolt of harmonic balancer in direction of engine rotation to TDC cyl. 1 marking (arrow):
Notes:
- Do not remove new cylinder head gasket from package until immediately before installing.
- Handle new gasket extremely carefully. Damage will cause leaking.
- Position new cylinder head gasket. Text (replacement part number) must be visible.
- Make sure dowel sleeves in cylinder block holes 12 and 20 are inserted and the cylinder head gasket is secured.
- Adjust camshafts in cylinder head to TDC cyl. 1.
- It must be possible to insert T10068 camshaft ruler into both shaft grooves.
Note:
- If camshaft cannot be inserted, rotate camshafts in direction of engine rotation past TDC position cyl. 1 and then return by rotating back to TDC position cyl. 1.
- Prepare cylinder head gasket for installation.
- Position cylinder head, insert new cylinder head bolts and tighten hand-tight.
- Tighten cylinder head bolts in specified sequence as follows:
Note:
- The longer cylinder head bolts must be inserted in the center bores in cylinder head.
- Tighten all bolts to 30 Nm.
- Then tighten all bolts to 50 Nm.
- Then turn all bolts 1/4 rotation (90 °) using a rigid wrench.
- Then turn all bolts an additional 1/4 rotation (90 °).
- The rest of the installation follows the reverse of the removal procedures.
Note:
- Make sure the O-ring for sealing the oil channel and the sealing ring in cover piece have been installed.
How to adjust valve timing.
- Install cylinder head cover and intake manifold, Cylinder head cover, removing and installing.
How to fill up new coolant.
Note:
- It is not necessary to re-tighten the cylinder head bolts after repairs.