Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip tray (VAG 1306) or drip tray for VAS 6100 (VAS 6208)
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Spring type clip pliers (VAS 5024A) or hose clip pliers (VAS 6340)
• Polydrive bit and drive socket (T10070) or Polydrive key (3452)
• Ignition coil puller (T40039)
• Silicone sealant (D 174 003 A2)
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 (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
Removing
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the engine cover.
- Remove the plenum chamber cover.
- Remove the battery.
- Remove the battery holder bolts - arrows - and remove the battery holder from the vehicle.
CAUTION!
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Install the transport strap again onto the cylinder head to be able to hold the cylinder head during removal.
- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Service and Repair.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Secure the camshafts and remove the sprocket and actuator from the camshafts. Refer to => [ Valve Timing, Adjusting ] Adjustments.
- Hold the timing chain - A - as shown to be able to lay it under the coolant connection - arrow -.
- Remove the bolts - 1 and 3 - and remove the exhaust manifold brace - 2 -.
- Loosen the nuts for the double clamp.
- Remove the 4 front exhaust pipe to the exhaust manifold nuts - 1 - and the suspended mount bolts - 3 -.
- Remove the front exhaust pipe - 2 - from the manifold and tie up firmly to the side.
• The flex joint in the front exhaust pipe must not be bent more than 10 degrees, otherwise it may be damaged.
- Disconnect the harness connector - 2 - for the oxygen sensor in the exhaust manifold.
- Remove the heat shield at the top of the front exhaust pipe and free up the wiring harness of the oxygen sensor in the exhaust manifold to the engine.
- Remove the wire bracket - 3 - bolts - arrows - at the Secondary Air Injection (AIR) valve.
- Remove the cylinder head bolts in the sequence specified.
• If the bolt - 2 - was not able to be pulled out using a magnet, loosen the bolts for the (T40070) one rotation, slide the (T40070) toward the right front (seen in direction of travel) and tighten the bolts again.
• A second mechanic is required to remove and install the cylinder head.
- Carefully remove the cylinder head.
Installing
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Only remove the new cylinder head gasket from its packaging immediately before installing.
• Handle the new gasket with extreme care. Damaging will lead to leaks.
• Replace the cylinder head bolts.
- Stuff clean cloths into the cylinders and chain compartment so that no dirt or abrasive powder can penetrate between the cylinder wall and piston and into the chain compartment.
- Do not allow dirt or abrasive powder to get into coolant either.
- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper below 100 grit).
- Carefully remove any metal particles, emery remains and the cloths.
- Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).
Note the shelf life date.
- Apply a bead of sealant - 1 - (front and rear) on the clean sealing surfaces as illustrated.
• The sealant bead must be 2.0 to 2.5 mm thick.
- Install the new cylinder head gasket - 2 -.
- Note the alignment pins in the cylinder block - arrows -.
- Apply a bead of sealant - 3 - (rear only), as illustrated, on the cylinder head gasket.
• The sealant bead must be 2.0 to 2.5 mm thick.
• The cylinder head must be installed within 5 minutes of applying the sealant.
- Install the cylinder head.
- Guide the timing chain over the coolant connection.
- Install the cylinder head bolts and tighten them hand tight.
- Tighten the cylinder head bolts - 1 through 12 - in the sequence shown as follows:
- Then tighten the bolts - 13 - to 10 Nm.
- Wipe off any sealant, which has leaked out.
The rest of the installation follows the reverse of the removal procedures. When doing this note the following:
• Remove the (T40069) from the cylinder block and install the locking bolt.
• Install the battery.
• Replace and fill coolant. Refer to => [ Draining and Filling ] Draining and Filling.