Valve Cover: Service and Repair
Cylinder head cover, removing and installing
Special tools and equipment
- VAS5024 assembly tool for spring-type clamps
- VAG 1331 torque wrench (5 to 50 Nm)
- T 10094 extractor
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.
- Remove cover at left above the battery.
- 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 engine cover -1-. To do so; remove 3 bolts (arrows).
- Remove noise insulation pan
- Remove intake hose between Mass Air Flow (MAF) sensor -G70- and throttle valve corbel module -J338-
- Remove radiator grill
- Remove securing bolts for lock carrier -1- at left and right.
- Fold out lock carrier with radiator toward the front (arrow).
- Unclip cover for ignition coils with power output stage.
- Disconnect connector (arrows) to ignition coils with power output stage and move wiring harness clear.
- Remove ignition coils using T10094 extractor.
- Disconnect connector from throttle valve control module (arrow).
- Open and close lid for expansion tank to release cooling system pressure.
- Disconnect coolant hoses -1- and -2- from throttle valve control module and plug hose ends.
- Now disconnect vacuum lines -1- and -2- at connecting piece of throttle valve control module.
- Unbolt center support between intake manifold and heat shield on exhaust manifold.
- Disconnect pressure hose at combination valve and connecting hose at cylinder head cover.
- Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
- Disconnect vacuum hose at combination valve.
- Unbolt intake manifold at support (arrow) at left rear of bracket from heat shiel on exhaust manifold.
- Unbolt intake manifold at support (arrow) at right rear of bracket from heat shieldhaust manifold.
- Disconnect connector from Secondary Air Injection (AIR) solenoid valve -N112- -1- and Secondary Air Injection (AIR) pump motor -V101- -2-.
- Remove secondary Air Injection (AIR) pump motor -V101-.
- Unbolt guide pipe for oil dipstick from intake manifold.
- Remove guide pipe for oil dipstick.
- Remove securing bolts for intake manifold and remove intake manifold together with the throttle valve control module.
- Remove intake manifold and place it on an appropriate surface so that the vacuum setting element is not damaged.
Note:
- Seal the intake channels in intake manifold and in cylinder head using a clean rag.
- Remove cylinder head cover.
Installing
Installation is reverse of removal, noting the following:
Notes:
- Replace cylinder head cover if damaged or leaking.
- First tighten intake manifold with lower part of intake manifold at cylinder head, then tighten bolts at rear supports.
- Top up coolant if necessary.
- Check DTC memory
- Adapt control module for engine electronics to throttle valve control module
- Perform work procedure "Procedure to follow after interruption of voltage supply"
- Read readiness code
- If DTC memory was erased or the Engine Control Module (ECM) was disconnected from the continuous B+ supply, the readiness code must be re-generated
WARNING:
- Observe the following for all installations, especially in engine compartment due to lack of room:
- Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
- Watch for sufficient clearance to all moving or hot components.
Tightening torques
