Cylinder Head, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Pry Lever 80-200
Wrench - Pin Type 3036
Hose Clamps - Up To 25mm 3094
Engine Bung Set VAS 6122
Puller - Toothed Belt Pulley T10320
Sealant.

Removal

Fig 1: Identifying Bolts -Arrows-

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-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Remove the affected camshaft timing chain from the camshaft, refer to CAMSHAFT TIMING CHAINS, REMOVAL FROM CAMSHAFTS .

-- Remove the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

-- Install the cylinder head, refer to: left LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING , right RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

Left Cylinder Head:

Fig 2: Identifying Toothed Belt Tensioning Roller And Bolt -Arrow-

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-- Remove the upper left coolant pipe. Refer to LEFT UPPER COOLANT PIPE, THROUGH 05.10, REMOVING AND INSTALLING .

-- Remove the high pressure pump toothed belt and the belt tensioning roller. Refer to HIGH PRESSURE PUMP TOOTHED BELT, REMOVING AND INSTALLING .

-- Loosen the toothed belt drive sprocket bolt -1- two turns using the Wrench - Pin Type 3036.

Fig 3: Identifying Toothed Belt Drive Gear Bolt

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-- Remove the toothed belt drive sprocket using the Puller - Toothed Belt Pulley T10320.

Fig 4: Identifying Toothed Belt Drive Gear, Removal

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-- Remove the bolts -arrows- and leave the rear toothed belt guard in its installation position.

Fig 5: Identifying Bolts -Arrows- And Rear Toothed Belt Guard

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-- Remove the bolt -2- for the oil dipstick guide tube.

Fig 6: Identifying Bolt -2- To Oil Dipstick Guide Tube

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NOTE:

Ignore -item 1-.

-- Mark the injector high pressure line for re-Installation.

Fig 7: Identifying Union Fittings -1 Through 4-

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-- Remove the union nuts -2- and -3-, free up and remove the high pressure line.

NOTE:

Ignore -1 and 4- and -arrow-.

-- Remove the T-connector from the coolant hose -arrow-.

Fig 8: Identifying T-Connector To Coolant Hose -Arrow-

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-- Disconnect the connector -1- on the Intake Flap Motor 2 -V275- -4-.

Fig 9: Carefully Push The Linkage -2- Off The Ball Studs -Arrow-.

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NOTE:

Ignore -item 2 and 3- and -arrows-.

Vehicles from 06/2010:

Fig 10: Identifying Power Steering Pump Hydraulic Hose -1- And Bolts -2-

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NOTE:

Place a cloth underneath to soak up any escaping power steering fluid.

-- Clamp off the power steering pump hydraulic hose -1- with a hose clamp Hose Clamps - Up To 25mm 3094.

-- Remove the bolts -2- and move the hydraulic line to the rear.

-- Seal any open lines and connections with a clean plug from the Engine Bung Set VAS 6122.

All Vehicles:

Fig 11: Identifying Clamp -Arrow- And Connecting Pipe -1-

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-- Loosen the clamp -arrow- and remove the exhaust gas recirculation pipe -1-.

Right Cylinder Head:

Fig 12: Identifying Union Fittings -1 Through 4-

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-- Remove the right intermediate pipe, refer to RIGHT INTERMEDIATE PIPE, REMOVING AND INSTALLING .

-- Remove the right upper coolant pipe. Refer to UPPER RIGHT COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and the high pressure line protective plate.

-- Mark the injector high pressure line for re-Installation.

-- Remove the union nuts -1- and -4-, free up and remove the high pressure line.

NOTE:

Ignore -items 2 and 3-.

-- Remove the engine lifting eyelet bolts -1- and -2-.

Fig 13: Identifying Wiring Harness -Arrow-

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-- Free up the wiring harness using Pry Lever 80-200 -arrow-.

-- Loosen the clamp -arrow- and remove the coolant line.

Fig 14: Loosening Clamp -Arrow- To Remove Coolant Pipe

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-- Disconnect the glow plug connectors for cylinders "2" and "3".

-- Disconnect the connector -1- on the Intake Flap Motor -V157-.

Fig 15: Identifying Lower Intake Manifold Bolts -Arrows-

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NOTE:

Ignore -arrows-.

-- Remove the connector -2- (orange) for EGR Temperature Sensor -G98- from the bracket and disconnect it.

Fig 16: Identifying Connectors -1 And 2-

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NOTE:

Ignore -item 1-.

NOTE:

Follow all the rules of cleanliness. Refer to FUEL SUPPLY, INJECTION SYSTEM AND CHARGING SYSTEM CLEAN WORKING CONDITIONS .

Fig 17: Identifying Bolts -Arrows- And Fuel Rail

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-- Remove the screws -arrows- and then move the fuel rail to the side with the hoses still attached.

NOTE:

Ignore -items 1 and 2-.

Continued for both sides:

Fig 18: Cylinder Head Bolt Loosening Sequence

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-- Loosen the cylinder head bolts in the sequence -1 to 8-.

-- Remove the bolts and the cylinder head carefully.

CAUTION:

Danger of damaging the glow plugs when Removal the cylinder head.

do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface

Installation

Install in reverse order of removal. Note the following:

Tightening specifications. Refer to CYLINDER HEAD OVERVIEW .

NOTE:

If the cylinder head is replaced the tensioning bracket needs to be replaced also.

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 cylinder block.

No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of leaks in cylinder head seal.

Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
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 is installed, only remove plastic base right before cylinder head is installed to protect open valves.

Risk of damaging valves and piston heads after working on valve train.

To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.

NOTE:

Replace any bolts that were tightened with an additional turn.

Replace self-locking nuts, sealing rings, seals and O-rings.

It is not permitted to re-work the cylinder heads on TDI engines

When Installation a replacement cylinder head with the camshaft installed, coat the contact surfaces between the hydraulic adjusting elements, the roller rocker levers and cam running surfaces with oil.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before Installation.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

-- Before positioning the cylinder head, adjust the crankshaft and camshafts to "TDC" :

Fig 19: Identifying Crankshaft Holder 3242

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The Crankshaft Holder3242 must be installed in the "TDC" position for the crankshaft -1-.

The camshafts on both cylinder head must be locked by the Camshaft Adjustment Pins T40060.

Fig 20: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And Adjustment Pin T40060
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The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

-- Note the cylinder head gasket identification:

Fig 21: Cylinder Head Gasket Identification

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Holes
Part Number

NOTE:

If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.

If the crankshaft drive is replaced, measure the piston projection in TDC to determine the new cylinder head. Refer to PISTON PROJECTION, MEASURING AT "TDC" .

The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

-- Clean any oil or grease off the sealing surfaces.

NOTE:

Note the expiration date of the sealing compound.

Fig 22: Cut Tube Nozzle At Front Marking

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Cut the tube nozzle at the front marking (nozzle diameter: approximately 5 mm).

Components that have had sealant applied to them must be bolted within 15 minutes.

Left Cylinder Head:

-- Apply a bead of sealant -1- and -2- on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.

Fig 23: Identifying Areas -1 And 2- To Apply Bead Of Sealant

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-- Apply the sealant in the amounts specified.

Fig 24: Identifying Dimensions -A To C-

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a = 7mm
b = 7 mm
c = 7 mm

-- Set cylinder head gasket in place.

-- Apply sealant beads -1- and -2- to the clean sealing surfaces as illustrated.

Fig 25: Identifying Areas -1 And 2- To Apply Bead Of Sealant

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Right Cylinder Head:

-- Apply a bead of sealant -1- and -2- on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.

Fig 26: Identifying Areas -1 And 2- To Apply Bead Of Sealant

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-- Apply the sealant in the amounts specified.

Fig 27: Identifying Dimensions -A To C-

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a = 7mm
b = 7 mm
c = 7 mm

-- Set cylinder head gasket in place.

-- Apply sealant beads -1- and -2- to the clean sealing surfaces as illustrated.

Fig 28: Identifying Sealant Beads -1 And 2-

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Continued for Both Sides:

Fig 29: Identifying Cylinder Head Gasket

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Pay close attention to alignment bushings in cylinder block -arrows-.
Pay attention to installation position of cylinder head gasket, marking "upper" (top) or part number must face toward cylinder head.

-- Set cylinder head in place.

-- Insert new cylinder head bolts and tighten by hand.

-- Tighten the cylinder head bolts, refer to Figure.

Fig 30: Cylinder Head, Tightening Specifications and Sequence

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NOTE:

There is no requirement to tighten the cylinder head bolts after repairs.

Left Cylinder Head:

-- Install the EGR pipe. Refer to EXHAUST GAS RECIRCULATION OVERVIEW .

-- Install oil dipstick guide tube, refer to OIL PAN UPPER SECTION OVERVIEW .

-- Installation the Upper Left Coolant Pipe LEFT UPPER COOLANT PIPE, THROUGH 05.10, REMOVING AND INSTALLING .

-- Install the rear toothed belt guard, the toothed belt tensioning roller and the high pressure pump toothed belt. Refer to HIGH PRESSURE PUMP TOOTHED BELT, REMOVING AND INSTALLING .

-- Install the hydraulic line. .

Right Cylinder Head:

-- Install the fuel rail. Refer to Diesel Fuel Injection .

-- Install the right upper coolant pipe, refer to UPPER RIGHT COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the right intermediate pipe, refer to RIGHT INTERMEDIATE PIPE, REMOVING AND INSTALLING .

Continued for Both Sides:

-- Install the high pressure lines. Refer to HIGH PRESSURE LINES, INSTALLING .

-- Install the cylinder head cover. For the left side, refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING and for the right side refer to RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

-- Install the camshaft timing chains. Refer to CAMSHAFT TIMING CHAINS, REMOVAL FROM CAMSHAFTS .

-- Change engine oil. Refer to Maintenance Booklet 406.

-- Replace coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Perform a leak test on the fuel system. Refer to FUEL SYSTEM LEAK TEST .