Cylinder Head Cover

Cylinder Head Cover

Special tools, testers and auxiliary items required

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

• Hose Clip Pliers (VAS 6362)

• Socket (T40055)

• Ratchet, Reversible (V.A.G 1331/1)

• Engine Bung Set (VAS 6122)


• Follow the safety precautions when working on the diesel direct injection system. Refer to => [ Safety Precautions ] Diesel Fuel Injection.

• Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Diesel Fuel Injection.

Always follow these instructions before and during work.

• Cylinder head cover overview. Refer to => [ Cylinder Head Cover Overview ] Cylinder Head Cover Overview.

Removing


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

• Route all lines and wires in their original locations.

• For example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum lines.

• Ensure sufficient clearance to all moving or hot components.

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

- Remove the protective strip.

- Disconnect the connectors from the fuel injectors - A -, the exhaust pressure sensor 1 (- B -) and the fuel pressure sensor (- C -).






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

- Unclip the wiring harness for the glow plugs from the wiring guide.


Always follow the procedure "glow plug connectors, disconnecting and installing".

- Disconnect the glow plug connectors. Refer to => [ Glow Plug Connector, Disconnecting and Connecting ] Glow Plug Connector, Disconnecting and Connecting.

- Remove the fuel return line bolt from the intake manifold.

- Reposition the hose clamp - arrow - using hose clip pliers (VAS 6362) and remove the line from the fuel rail.






- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).

- Cover the return line connections with a cloth.

- Remove the fuel return line connections on the fuel injectors. Pull them upward to release them - arrow -.






• Follow the rules of cleanliness.

• Do not let any dirt to get into the disconnected return lines or into the connections for the fuel injection units.

- Reposition the hose clamp using hose clip pliers (VAS 6362) and remove the fuel return line.

- Reposition the hose clamp - 4 - using hose clip pliers (VAS 6362) and remove the fuel return line at the high pressure fuel pump.






- Seal the lines so that the fuel system is not contaminated by dirt, etc.

- Remove the fuel return line and lay the lines in front of the intake manifold.

- Disconnect the connector from the charge pressure actuator position sensor - arrow - at the turbocharger vacuum diaphragm and guide the line out of the retainers.






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






- Remove the line guide on the fuel rail and lay it aside.

- Remove the vacuum hose from the cylinder head cover.

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

- Disconnect the connector - 1 - from the engine coolant temperature sensor on radiator outlet, open the clips - arrows - and remove the upper toothed belt guard.






- Remove the crankcase ventilation hose between the intake tube and the cylinder head cover.

• The crankcase ventilation hose is destroyed when it is removed.

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

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

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






- Remove the fuel injectors. Refer to => [ Fuel Injector ] Fuel Injector.

- Remove the cylinder head cover bolts in sequence - 7 through 1 -.






- Remove the cylinder head cover.

Installing

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

• Replace the cylinder head cover gasket if it leaks or is damaged. Refer to the Parts Catalog.

• When installing the high pressure line or fuel lines, make sure no dirt or contaminants enter the fuel system.

• Only remove the sealing plugs right before installing the fuel lines.

• Do not change the angles of the high pressure lines

• Make sure line connections are securely fastened.

• Do not swap the supply and return lines.

- First, tighten the cylinder head cover bolts by hand in sequence - 1 through 7 -.






- Tighten the cylinder head cover bolts in sequence - 1 through 7 - to specification.

• Tightening specification, see - item 14 - in the => [ Cylinder Head Cover Overview ] Cylinder Head Cover Overview.

- Install the upper toothed belt guard.

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






• The camshaft gear is not shown in the illustration.

- Press the upper 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 upper toothed belt guard.

- Tighten the high pressure line union nuts by hand.

- Make sure the high pressure line is free of tension.

- Use the torque wrench (5-50 Nm) (V.A.G 1331) with the ratchet, reversible (V.A.G 1331/1) and the socket (T40055) to tighten the high pressure line.






Tightening Specifications

• Cylinder head cover overview, refer to => [ Cylinder Head Cover Overview ] Cylinder Head Cover Overview.

• Fuel system overview, refer to => [ Fuel Rail and Injectors Overview ] Service and Repair.

- Fill the fuel system, refer to => [ Fuel System, Filling and Bleeding ] Fuel System, Filling and Bleeding.