Cylinder Head Cover

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 - to the vacuum reservoir.






- Disconnect the electrical connector - 1 -.

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






when Removing the Left Cylinder Head Cover

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






Continuation for Both Sides

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






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






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

- Free up the wiring harness.






Always observe the rules for cleanliness when working on the injection system. Refer to => [ Clean Working Conditions and Fuel System Work Instructions ] Clean Working Conditions and Fuel System Work Instructions.

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

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

- Loosen the high pressure fuel line union nuts - 1 through 6 - using the tool insert, AF 19 (V.A.G 1331/5) or socket 14 mm (3150) or the socket (T40055).






- Remove high pressure fuel lines.

- Remove the sealing cap bolts - arrows -.






- Pull the sealing caps upward and turn them 90° (1/4) turn.






- Remove the tensioning plate nuts - arrows -.

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






• Mark the allocation of the injectors to the cylinder.

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

- Loosen the cylinder head cover bolts - arrows - diagonally, starting from the outside and working toward the inside.






- Remove the bolts and the cylinder head cover.

Installing

Install in the reverse order of removal. Note the following:

• Replace the cylinder head cover gaskets if they are damaged.

• Replace the 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, diagonally and in steps, starting from the inside and working toward the outside.

Injector Installation Information:

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

• Always use new seals. Coat 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 vice jaws 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 injector line and tensioning bracket must be replaced when replacing the injector.

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

- Install the fuel injectors.

- Tighten the high pressure line union nuts hand tight.

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

- Tighten the high pressure lines:

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

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

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

- Inspect the fuel system for leaks. Refer to => [ Fuel System, Checking for Leaks ] Fuel System, Checking for Leaks.

Tightening Specifications