Valve Cover: Service and Repair

Cylinder Head Cover

Special tools, testers and auxiliary items required

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

• Ratchet, Reversible (V.A.G 1331/1)

• Tool Insert AF 19 (V.A.G 1331/5)

• Puller (T10055)

• Socket (T40055)

Removing

• The following removal and installation procedure is for the left cylinder head cover. The procedure for the right side is identical except for a few steps.

- Disconnect the vacuum hose - 2 - from the vacuum reservoir.





• Ignore - 1 -.

- Place a clean cloth under the separating location to catch any fuel that may leak out.





CAUTION!
Always observe the rules for cleanliness when working on the injection system. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Remove the fuel supply hose - 6 - from the fuel filter.

- Remove the fuel hose - 3 and 5 - to the fuel cooler.

- Remove the bolts - 1 and 2 - and the nut - 4 -.

- Free up the fuel lines at the plenum chamber bulkhead and lay the fuel filter aside with the fuel hoses connected.

- Remove the wiring connector - 1 -.

- Remove the high pressure fuel lines - 2 - and the overflow oil line - 3 -.





For the Left Cylinder Head Cover

- Remove the engine cover bracket - 1 -, the bolts - arrows - and the upper intake manifold.





Continuation for All

- Lift the tab - 1 -, turn the oil filler tube counterclockwise - arrow - and remove the tube.





- Remove the wiring harness bracket bolt - 5 - from the cylinder head cover.





- Disconnect the connectors - 1 through 4 - from the fuel injectors.

- Free up the wiring harness.





CAUTION!
Always observe the rules for cleanliness when working on the injection system. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Pull the release pins upward - arrow - and remove the return line connections from the injectors.

- Mark the assignment of the high pressure lines to the injectors.

- Loosen the high pressure line union nuts - 1 through 6 - using (V.A.G 1331/5) or (3150) and the (T40055).





- Remove the high pressure lines.

- Remove the injector covers bolts - arrows -.





- Pull the covers upward and rotate them 90° (1/4 turn).





- Remove the injector tensioning plate nuts - arrows -.

- Remove the injectors using (T10055) and (T10055/1).





CAUTION!
• Mark the allocation of the injectors to the cylinder.

• Used injectors may only be installed in the same cylinder.

- Loosen the cylinder head cover bolts - arrows - in a diagonal sequence.





- Remove the bolts and the cylinder head cover.

Installing

Installation is performed in reverse order of removal, noting the following:

• Replace the cylinder head cover gaskets if damaged.

• Replace gaskets, seals and O-rings.

• Hose connections and charge air system hoses must be free of oil and grease before installing.

• Secure all hose connections using hose clamps appropriate for the model type. Refer to the parts catalog.

- Tighten the cylinder head cover bolts in a diagonal sequence and in stages.

Injector Installation Information

• Make sure the injectors and their installed locations are clean before installing. Clean the injector shaft in the cylinder head with a clean cloth if necessary. Do not use any sharp tools and be careful not to damage it.

• Always use new seals. Lubricate all the seals with installation oil or assembly oil before installing.

• The fuel injectors must not be damaged. To remove the used copper sealing ring from the fuel injector, clamp the sealing ring carefully in a vise until the clamping jaws on the vise prevent the ring from turning. Pull the fuel injector out of the copper sealing ring by hand with a slight twisting and pulling motion.

• The high pressure line and tensioning bracket must be replaced when replacing the injector.

• When installing, the fuel injectors and injection lines may only be installed on the same cylinder as before.

- Install the fuel injectors.

- Tighten the high pressure line union nuts by hand.

- Make sure the high pressure lines are seated free of stress.

- Tighten the high pressure lines, refer to one of the following:

Using a 14 mm wrench, refer to => [ Tightening the High
Pressure Line to the Fuel Rail with a 14 mm Wrench ] Cylinder Head Overview.

Using a 17 mm wrench, refer to => [ Tightening the High
Pressure Line to the Fuel Injector with a 17 mm Wrench ] Cylinder Head Overview.

Using a 19 mm wrench, refer to => [ Tightening the High
Pressure Line to the Fuel Rail with a 19 mm Wrench ] Cylinder Head Overview.

- Inspect the fuel system for leaks. Refer to => [ Fuel System, Performing Leak Test ] Fuel System, Performing Leak Test.

Tightening Specifications