Cylinder Head Cover

Cylinder Head Cover

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Pliers (3314)

Removing

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the noise insulation from the injectors.

- Disconnect the following connectors: the fuel injectors - A -, the exhaust pressure sensor 1 - B - and the fuel rail pressure sensor - C -.






- Remove the coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.


Be careful not to damage the wire connection when removing the connectors. Otherwise the whole wiring harness will have to be replaced. Do not squeeze the pliers (3314) too hard when removing the connectors otherwise the protective sleeve will get damaged.

- Position the pliers (3314) with the groove - arrow A - on the collar of the protective sleeve - arrow B - and pull the connector off the glow plugs.






- Carefully remove the connector in the - direction of the arrow - from the glow plug.






- Remove the nut on the intake manifold for the fuel return line, open the clamp - arrow - and disconnect the line from the rail.






- Remove the fuel return line connections on the fuel injectors. Press the connection downward and pull the center piece upward.






• Pay attention to cleanliness. Do not let any dirt to get into the disconnected return lines or into the connections for the fuel injectors.

- Remove the complete return line and lay it in front of the intake manifold.

- Disconnect the connector from the charge pressure actuator position sensor - arrow - on the turbocharger and guide the wire out of the mounts.






- Disconnect the connector on the fuel pressure regulator valve - arrow -.






- Remove the wire guide from the rail and move it to the side.

- Remove the vacuum line from the cylinder head cover. Remove the remaining vacuum lines from the bracket on the cylinder head cover.

- Remove the upper toothed belt guard.

- Remove the breather line between the cylinder head cover and the intake hose. To do this press the quick release fastener together.

- Remove the high pressure line between the high pressure pump and the rail.

- Remove the high pressure lines between the rail and the fuel injectors.

- Remove the bolts - arrows - and remove the rail.






- Remove the fuel injectors. Refer to => [ Fuel Injectors ] Service and Repair.

- Remove the cylinder head cover bolts and remove the cover.

Installing

Install in the reverse order of removal. Note the following:

• Replace the bolt bushings if damaged.

- Install and tighten by hand the cylinder head cover bolts in sequence - 1 through 7 -.

- Tighten the bolts in sequence - 1 through 7 - to 10 Nm.






- Make sure the cylinder head cover is correctly attached to the toothed belt guard.

• The camshaft sprocket is not shown in the illustration.

- Press the toothed belt guard in the area with the clips - arrows - against the cylinder head cover until the clips engage with each other. Use a screwdriver to press the guard if necessary.






- Check the clearance between the hub and the toothed belt guard.

- Install the high pressure lines. Refer to => [ High Pressure Lines ] Service and Repair.