Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Guide Pins & Handle - 1112 MM (3070)

• Diesel Injection Pump Locking Pin (3359)

• Crankshaft Stop (T10050)

• Camshaft Gear Counter-Holder (T10051)

• Puller (T10052)

• Socket Insert XZN 10 (T10385)

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

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Drip Tray for VAS 6100 (VAS 6208)

• Spring-Type Clip Pliers (VAS 6499)

• Pry Lever-Rmv Outside Mirror (80-200)

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all wires and lines so that the original path is followed.

• Ensure sufficient clearance to all moving or hot components.

• Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the tears have a width of maximum 0.5 mm.

Removing

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

- Remove the noise insulation.

• To perform this procedure, the ground cable must be disconnected from the battery. Check if a coded radio is installed. If so, obtain the anti-theft code beforehand.

- Remove the battery, the battery tray bolts - arrows - and tray.






Risk of destroying electronic components when disconnecting the battery.

• Observe the measures for disconnecting the battery.

- Remove the air filter housing with the Mass Airflow (MAF) sensor and connecting pipe. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the charge air cooler. Refer to => [ Charge Air Cooler ] Charge Air Cooler.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

- Remove the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.

- Remove the camshaft sprocket and hub. Refer to => [ Camshafts ] Service and Repair.

- Remove the NOx reduction catalytic converter. Refer to => [ NOx Reduction Catalytic Converter ] NOx Reduction Catalytic Converter.

- Remove the heated oxygen sensor and the oxygen sensor heater. Refer to => [ Heated Oxygen Sensor G39 with Oxygen Sensor Heater Z19 ] Heated Oxygen Sensor G39 with Oxygen Sensor Heater Z19.

- Remove the exhaust pressure sensor 1. Refer to => [ Exhaust Pressure Sensor 1 G450 ] Service and Repair.

- Remove the exhaust gas temperature sensor 2. Refer to => [ Exhaust Gas Temperature Sensor 2 G448 ] Exhaust Gas Temperature Sensor 2 G448.

- Remove the exhaust gas temperature sensor 3. Refer to => [ Exhaust Gas Temperature Sensor 3 G495 ] Exhaust Gas Temperature Sensor 3 G495.

- Remove the exhaust gas temperature sensor 4. Refer to => [ Exhaust Gas Temperature Sensor 4 G648 ] Exhaust Gas Temperature Sensor 4 G648.

- Remove the EGR temperature sensor. Refer to => [ EGR Temperature Sensor G98 ] Service and Repair.

- Disconnect the connector and remove it from the crankcase ventilation hose - 1 -.






- Free up the vacuum hose - arrows - on the air guide pipe.

- Remove the bolt - 2 - and tilt the air guide pipe with the intake hose backward and remove it from the turbocharger.

- Remove the bolt - arrow -.






- Unclip the pre-heater pipe - 1 - and remove it from the bracket.

- Remove the heat shield boot.






- Remove the vacuum hose - 2 - from the turbocharger vacuum diaphragm.






- Release and disconnect the connector - 1 - from the charge pressure actuator position sensor.

- Remove the vacuum line - 1 - from the brake booster - 2 -.






- Remove the vacuum line - 2 - from the vacuum pump - 1 -.






- Remove the vacuum hose - A - from the cylinder head cover.






- Disconnect and remove the connector - 2 - from the wastegate bypass regulator valve - 1 -.






- Remove the nuts - arrows - from the wastegate bypass regulator valve - 1 -.

- Set the vacuum line, vacuum hoses and wastegate bypass regulator valve aside.

- Release and disconnect the connector - arrow A - and free up the wires.






with a Direct Shift Gearbox (DSG(R))






- Loosen the hose clamps - arrows - and remove the coolant hoses from the transmission fluid cooler.

Continuation for All






- Remove the bolt - arrow -.

- Unclip the wires and hoses using the pry lever-rmv outside mirror (80-200) from the air guide pipe - 1 -.

- Loosen the hose clamp - 2 - and remove the air guide pipe - 1 -.

- Remove the plug - arrow B -.






- Remove the engine lifting eye from the cylinder head.

- Remove the bolts - arrows -.






- Remove the pulsation damper - 2 -.

- Remove the bolts and then remove the connection - 3 - on the cylinder head.






- Release and disconnect the connector - 4 -.

- Release and disconnect the connector - 1 - from the oil pressure switch.






- Release and disconnect the connector - 2 - from the Exhaust Gas Recirculation (EGR) cooler.






- Free up the wires near the cylinder head.

- Loosen the clamp - 1 - for the connection between the turbocharger and the particulate filter and remove it.






• The illustration shows the clamp bolt - 1 - from underneath. This can also be installed from above in some cases.

- Remove the bolt - 1 - on the upper particulate filter bracket.






- Remove the nut - arrow - and then remove the bracket - 1 - on the upper cylinder head.






- Remove the bolts - arrows -.






- Free up the wires on the turbocharger.

- Release and disconnect the connectors - 1 - on the EGR vacuum regulator solenoid valve.






- Release and disconnect the connectors - 3 - from the throttle valve control module.

- Remove the bolt - 1 - for the oil dipstick tube.






- Remove the bolts - upper arrows - from the support - 1 -.






- Remove the bolts - 2 - and remove the connecting tube - 1 -.






- Release and disconnect the connector - 1 - from the camshaft position sensor.






- Unclip the connector on the coolant pipe.

- Remove the right drive axle heat shield bolts - 1 - and shield






- Loosen the clamp - 2 - and remove it.






- Remove the bolts - arrows - and remove the EGR pipe - 1 -.

- Loosen the nuts - 1 and 2 - from the particulate filter bracket.






- Remove the bolts - arrows A -.






- Remove the nut - arrow B -.

- Remove the sensor wire - 1 - to the EGR pipe.

- Remove the EGR pipe from the seal - 2 - in the intake tube - 3 -.

- Remove the bolts - 1 and 3 -.






- Remove the banjo bolts - 4 and 5 -.

- Loosen the fitting - 2 - and then remove the oil supply line - 1 - from the turbocharger - 3 -.






- Remove the oil line together with the turbocharger supports.

- Remove the rear toothed belt guard bolt - arrow -.






- Remove the toothed belt tensioning roller nut - item 6 - in the => [ Toothed Belt Drive Overview ] Toothed Belt Drive Overview.

- Remove the cylinder head bolts.






• Follow the sequence - 1 through 10 - when loosening the cylinder head bolts.

• A second technician is needed when removing the cylinder head.

• The toothed belt tensioning roller is pulled off the stud bolt when lifting the cylinder head out.

• Free up and remove the wires for the camshaft position sensor when removing the cylinder head.

- First, lift the cylinder head on the transmission side and remove it from out of the toothed belt guard.

- Be careful not to let the toothed belt tensioning roller fall.

- Carefully lay the cylinder head down, on a piece of wood, if necessary.

Installing

Install in reverse order of removal. When doing this note the following:

• Always replace the cylinder head bolts.

• Carefully remove any sealant residue from the cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sandpaper, the grit must not be below 100.

• Thoroughly remove all sanding and grinding residue.

• Only unpack the new cylinder head gasket immediately prior to installation.

• Handle the gasket carefully. Damage to the silicone layer and in the areas of the recesses may result in leaks.

- Before installing the cylinder head, remove the crankshaft stop (T10050) and rotate the crankshaft back opposite of the engine rotation direction until all of the pistons are nearly even under Top Dead Center (TDC).

- Place the cylinder head gasket with the identification - arrows - upward.






- Slide the guide pins (3070) into the outer bores on the intake side.






• The tensioning roller must be placed on the stud bolt when positioning the cylinder head.

- Install the cylinder head, insert the eight cylinder head bolts and tighten them by hand.

- Remove the guide pins using the guide pin handle.

- Install the 2 remaining cylinder head bolts hand tight in the outer opening on the intake side.

- Tighten the cylinder head bolts in the sequence - 1 through 10 -, in four steps as follows:






1 - Tighten the bolts using a torque wrench:

Step 1= tighten to 30 Nm

Step 2 = tighten to 50 Nm

2 - Tighten the bolts using a ratchet:

Step 3 = tighten an additional 90° (1/4) turn

Step 4 = tighten and additional 90° (1/4) turn

- Attach the rear toothed belt guard to the cylinder head.






- Install the camshaft sprocket and the hub, refer to => [ Camshafts ] Service and Repair.

- Lock the camshaft and the high pressure pump using the diesel injection pump locking pin (3359). Refer to => [ Toothed Belt ] Toothed Belt.

- Rotate the crankshaft in engine rotation direction to TDC and lock it with the crankshaft stop (T10050). Refer to => [ Toothed Belt ] Toothed Belt.






- Install the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.

• Replace the seals, self-locking nuts and the clamp for the particulate filter.

• When installing, bring all cable ties back to same positions.

Make sure to follow the installation sequence when attaching the particulate filter:











- Install the exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Removal and Replacement.

- Fill the coolant. Refer to => [ Draining and Filling ] Procedures.

- Perform a road test and then check all the Diagnostic Trouble code (DTC) memories. Refer to the vehicle diagnostic tester.

Tightening Specifications