Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Guide pins (3070)
• Securing pin (3359)
• Crankshaft stop (T10050)
• Counter-holder tool (T10051)
• Removal tool (T10052)
• Multipoint socket (T10385)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Drip tray for workshop crane (VAS 6208)
• Engine bung set (VAS 6122)
CAUTION!
• Follow the safety precautions when working on the diesel direct injection system. Refer to --> [ Safety Precautions ] Safety Precautions.
• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.
Always follow these instructions before and during work.
• --> [ Toothed Belt Drive Assembly Overview ] Toothed Belt Drive Assembly Overview.
• --> [ Cylinder Head Cover Assembly Overview ] Cylinder Head Cover Assembly Overview.
• --> [ Cylinder Head Assembly Overview ] Cylinder Head Assembly Overview.
• --> [ Turbocharger with Exhaust Manifold and Attachments Assembly Overview ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview
• --> [ Charge Air Cooler Components Assembly Overview ] Charge Air Cooler Components Assembly Overview.
• --> [ Intake Manifold with Attachments Assembly Overview ] Intake Manifold With Attachments Assembly Overview.
• --> [ Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
• --> [ Exhaust Gas Recirculation System Components Assembly Overview ] Service and Repair.
• Hose connections are secured with either spring-type or clamp-type clips.
• Always replace clamp-type clips with spring-type clips.
• Pliers for spring clamps (VAS 6362) or hose clamp pliers (VAS 6340) are recommended for installing spring clamps.
• All cable ties which are opened or cut open when removing cylinder head, must be replaced in the same position when installing cylinder head.
Removing
• To perform the procedure, the battery ground cable must be disconnected. Check whether a coded radio is installed. If so, obtain antitheft coding beforehand.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• 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.
• Ensure sufficient clearance to all moving or hot components.
- Remove engine cover. Refer to --> [ Engine Cover ] Engine Cover.
- Remove air filter housing. Refer to --> [ Air Filter Housing ] Air Filter Housing.
CAUTION!
Electronic components could be destroyed when the battery is disconnected:
• Follow the required steps when disconnecting the battery.
- With the ignition switched off, disconnect ground cable - arrow - to the battery..
- Remove battery and battery tray - arrows -.
- Remove cylinder head cover. Refer to--> [ Cylinder Head Cover ] Cylinder Head Cover.
- Remove toothed belt from the camshaft. Refer to --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning.
- Remove camshaft sprocket and hub. Refer to --> [ Camshafts ] Camshafts.
- Disconnect connector from the EGR vacuum regulator solenoid valve- 1 - and throttle valve control module - 3 -.
- Loosen clamp - 4 - and remove charge air hose.
- Remove oil dipstick bracket - arrow -.
- Disconnect connecting pipe - 2 -.
- Remove connecting pipe --> [ 31 Connecting Pipe ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview.
- Remove oil supply line. Refer to --> [ Oil Supply Line to Turbocharger ] Service and Repair.
- Unclip wiring harness to ECM from wiring guide - arrow -.
- Remove vacuum pump. Refer to --> [ Vacuum Pump ] Service and Repair.
- Disconnect charge pressure actuator position sensor - 2 - at the turbocharger vacuum diaphragm.
- Disconnect vacuum hose - 3 - at turbocharger vacuum diaphragm.
- Disconnect the black connector for exhaust gas temperature sensor 1 - 2 - at engine bulkhead.
- Guide line out of the retainers on the engine bulkhead and turbocharger.
- Remove insulation pan.
- Remove right drive axle heat shield - arrows -.
- Remove charge air pipe bolts --> [ (item 15) Charge Air Pipe ] Charge Air Cooler Components Assembly Overview and the connecting hose --> [ (item 13) Connecting Hose ] Charge Air Cooler Components Assembly Overview from the pulsation damper on the turbocharger.
- Mark installation position of the exhaust gas temperature sensor 1 --> [ (item 37) , 45 Nm ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview and remove it.
- Remove heat shield and disconnect connector from the exhaust pressure sensor 2 --> [ 1 ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Remove control wire between the exhaust gas recirculation housing and the exhaust pressure sensor 2 --> [ 8 Control Wire, 23 Nm ] Service and Repair.
- Remove bolts and bracket with the exhaust pressure sensor 2 and lay them aside (the control wire to the particulate filter remains connected).
- Remove lower bracket --> [ (item 26) Bracket ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview for particulate filter.
• Remove the nuts above the bracket with the ratchet wrench (T10384).
- Remove exhaust gas recirculation filter --> [ 9 Filter ] Service and Repair.
- Disconnect connector - arrow - from coolant temperature sensor and guide the wire out.
- Remove particulate filter from the upper bracket --> [ 31 Bracket ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview and remove bracket at cylinder head.
- Remove clamp --> [ 10 Securing Clamp, 7 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview between the particulate filter and turbocharger.
- Remove banjo bolt --> [ (item 24) Banjo Bolt ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview from the turbocharger support.
- Remove hex stud bolt --> [ (item 17) Stud Bolt ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview from the turbocharger support.
- Rotate lower section of the support 90° and remove support downward from the upper section.
- Remove coolant hoses at cylinder head coolant connections.
- Remove toothed belt guard bolt - arrow - downward.
- Remove nut --> [ 5 Idler Roller ] Toothed Belt Drive Assembly Overview for the toothed belt tensioning roller --> [ 7 Tensioning roller ] Toothed Belt Drive Assembly Overview.
- Disconnect camshaft position sensor connector - arrow -.
- Drain coolant. Refer to --> [ Cooling System, Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Remove cylinder head bolts in sequence - 1 to 10 -.
• 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.
• The turbocharger oil return line is pulled out of the supported when lifting the cylinder head out.
• Make sure all necessary electrical lines are loosened!
- Raise cylinder head at the transmission side first and guide it back out of the toothed belt guard. Make sure the toothed belt tensioning roller does not fall down.
- Lay the cylinder head down so that the oil return line is not bent. Place a wooden block under the exhaust manifold if necessary.
Installing
CAUTION!
The sealing surfaces could be damaged:
• Carefully remove sealant residue from cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging the cylinder block:
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Risk of the cylinder head seal leaking:
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves:
• If a replacement cylinder head is installed, only remove the accompanying plastic base immediately before installing to protect the open valves.
Risk of damaging valves and piston heads after working on valvetrain:
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Before installing, check if the oil return pipe decoupling element is bent and therefore stretched. If that is the case, tiny cracks can form that can lead to leaks. Replace the oil return pipe before installing the cylinder head if necessary.
• Always replace cylinder head bolts.
• Replace gaskets, seals, self-locking nuts and clamps.
• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.
• Thoroughly remove all sanding and grinding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
- Before positioning cylinder head, remove crankshaft stop (T10050) and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under TDC.
- Place cylinder head seal with identification upward.
- Slide guide pins (3070) into the outer bores on the intake side to center.
• The tensioning roller must be placed on the studs when positioning the cylinder head.
- Install cylinder head, insert eight cylinder head bolts and tighten them by hand.
- Remove guide pins through the bolt holes with the guide pin handle from (3070). Insert cylinder head bolts.
- Tighten cylinder head in sequence indicated, in four stages as follows:
1 - Tighten using torque wrench:
Step I = 35 Nm
Step II = 60 Nm
2 - Tighten further using a solid wrench:
Stage III = 1/4 additional turn (90°)
Step IV = 1/4 turn (90°)
- Secure toothed belt guard on the back of the cylinder head.
• Tightening specifications --> [ item 14, 20 Nm ] Toothed Belt Drive Assembly Overview.
- Install camshaft sprocket and the hub. Refer to --> [ Camshafts ] Camshafts.
- Secure camshaft and the high pressure fuel pump with rig pin (3359).
- Now rotate crankshaft in direction of engine rotation to TDC and secure it with the crankshaft stop (T10050).
- How to install and tension the toothed belt. Refer to --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning.
The additional numbered steps must be followed to ensure the particulate filter with the NOx reduction catalytic converter is installed correctly:
• After installing the particulate filter with NOx reduction catalytic converter, make sure it is free of tension.
• Always replace self-locking nuts, seals, gaskets and clamps.
CAUTION!
The decoupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:
• Do not bend the decoupling element more than 10°.
• Do not stretch the decoupling element.
• Do not damage the wire mesh on the decoupling element.
- Position lower bracket --> [ (item 26) Bracket ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview with the nuts on the cylinder block and on the particulate filter. (Do not tighten nuts.)
- Position new clamp with a new gasket between the particulate filter and turbocharger (do not tighten clamp):
• Make sure clamp is in correct installation position --> [ Clamp Installation Position Between the Particulate Filter and Turbocharger ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
- Install exhaust gas recirculation filter --> [ 9 Filter ] Service and Repair.
- Position a new clamp between particulate filter and exhaust gas recirculation filter (do not tighten clamp):
• Make sure clamp is in correct installation position --> [ Clamp Installation Position Between the Particulate Filter and Exhaust Gas Recirculation Filter ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
- Position particulate filter on the upper bracket --> [ 31 Bracket ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview with bolt. (Do not tighten bolt.)
- Tighten mounting elements in the following sequence:
- Clamp between particulate filter and turbocharger.
• Tightening specifications --> [ 10 Securing Clamp, 7 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Lower bracket to cylinder block:
• Tightening specifications --> [ (item 25) 23 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Lower bracket to particulate filter:
• Tightening specifications --> [ (item 24) 23 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Upper bracket to particulate filter:
• Tightening specifications --> [ (item 32) 23 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Upper bracket to cylinder head:
• Tightening specifications --> [ (item 32) 23 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Clamp between particulate filter and exhaust gas recirculation filter:
• Tightening specifications --> [ 21 Securing Clamp, 3.5 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
Further installation is performed in reverse order. When doing this note the following:
• Replace self-locking nuts and seals.
• Position charge air pipe connecting hose before securing the turbocharger.
• Note exhaust gas temperature sensor 1 installation position.
• Replace banjo bolt with the turbocharger support gaskets and oil return pipe O-rings.
• Do not stretch oil return pipe decoupling element when installing the turbocharger support.
• Make sure lines connections are securely fastened.
- Install cylinder head cover. Refer to --> [ Cylinder Head Cover ] Cylinder Head Cover
- Install right drive axle heat shield - arrows -.
Manual transmission tightening specification, refer to --> Manual Transmission Manual Transmission/Transaxle
DSG transmission tightening specification, refer to --> Automatic Transmission Automatic Transmission/Transaxle
Tightening Specifications
• --> [ Toothed Belt Drive Assembly Overview ] Toothed Belt Drive Assembly Overview
• --> [ Cylinder Head Cover Assembly Overview ] Cylinder Head Cover Assembly Overview
• --> [ Cylinder Head Assembly Overview ] Cylinder Head Assembly Overview
• --> [ Turbocharger with Exhaust Manifold and Attachments Assembly Overview ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview
• --> [ Charge Air Cooler Components Assembly Overview ] Charge Air Cooler Components Assembly Overview
• --> [ Intake Manifold with Attachments Assembly Overview ] Intake Manifold With Attachments Assembly Overview
• --> [ Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
• --> [ Exhaust Gas Recirculation System Components Assembly Overview ] Service and Repair
- Observe notes for connecting battery.
- Fill with coolant. Refer to --> [ Cooling System, Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Fill the fuel system. Refer to --> [ Fuel System, Filling ] Fuel System, Filling.