Cylinder Head

Special tools and workshop equipment required

Ignition Coil Puller T40039
Assembly Tool T10352 and Assembly Tool T10352/1
Counter Hold Tool T10355
Locking Pin T40011
Engine Bung Set VAS 6122

Removing

NOTE:

During installation, cable ties must be installed at the same location.

Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the VAS 6122.

-- Remove the engine cover -arrows-.

Fig 1: Removing Engine Cover

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-- Remove the bolts -arrows- and air guide.

Fig 2: Removing Bolts -Arrows- And Air Guide

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-- Remove both the lower air guide and the air guide hose.

-- Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Fig 3: Air Flow Housing, Electrical Connector And Guide Hose

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-- Remove the air guide hose -2-.

-- Remove the bolt -4- and the air filter housing.

NOTE:

Ignore -3-.

-- Loosen the hose clamp -2-.

Fig 4: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

-- Disconnect the electrical connectors -arrow- and free up the electrical wire.

NOTE:

Ignore -1 and 3-.

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

-- Open the coolant reservoir cap.

-- Remove front exhaust pipe with the catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .

-- Remove the right front wheel.

-- Remove the noise insulation. Refer to Removal and Installation .

-- Remove the right noise insulation -arrows-.

Fig 5: Identifying Right Drive Axle Heat Shield

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-- Remove the frame for the noise insulation. Refer to Removal and Installation .

-- Remove the air guide pipe -1 and 2-.

Fig 6: Air Cooler Air Duct

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

-- Remove the bolt -1- and remove the air guide pipe downward.

Fig 7: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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NOTE:

Ignore items -2, 3 and 4 and the arrow-.

-- Remove the bolts -arrows-.

Fig 8: Air Guide Pipe And Bolts

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-- Lift the clamps -1 and 2- and remove the air guide pipe.

-- Disconnect electrical connectors -1 and 2- and free up electrical wire -arrows-.

Fig 9: Identifying Turbocharger Electrical Connectors

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-- Remove bolts -1 and 2- and remove the turbocharger support.

Fig 10: Identifying Turbocharger Support And Bolts

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-- Remove the banjo bolt -2- and move the coolant line to the side.

Fig 11: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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-- Remove the bolts -1- on the oil return line.

-- Remove the bolt -3- on the oil supply line.

NOTE:

The installation location is shown with the engine removed.

-- Remove the air guide pipe bolt -arrow-.

Fig 12: Locating Air Guide Pipe Bolt

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-- Remove the air guide pipe; to do this, loosen the hose clamp -1-.

-- Press the release buttons and remove the air guide hose -2-.

-- Disconnect the hose for the crankcase ventilation - 1 -.

Fig 13: Crankcase Ventilation, Tightening Sequence

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-- Remove the bolts -arrows- and remove the crankcase ventilation.

-- Remove the coolant hose -1-.

Fig 14: Locating Coolant Hose Bolts

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-- Remove the bolts -2 and 3-.

-- Remove the coolant hoses -1 and 2-.

Fig 15: Identifying Coolant Hoses

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-- Disconnect the connector -4- and free up the wiring harness.

-- Remove the vacuum hose from the vacuum pump -5- and free it up.

-- Remove the bolt -3- and the coolant line.

NOTE:

Be careful of the ground wire -arrow- when installing.

NOTE:

The installation location is shown with the engine removed.

-- Remove the heat shield -arrows-.

Fig 16: Turbocharger And Heatshield

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-- Disconnect the oil supply line from the turbocharger -1-.

-- Disconnect the connectors on the ignition coils and free up the wiring harness.

-- Remove the ignition coils with the T40039.

Fig 17: Identifying Ignition Coil Puller T40039 To Remove Ignition Coils

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-- Remove the coolant hoses on the rear of the cylinder head.

-- Disconnect the connectors -1 through 4-.

Fig 18: EVAP Filter Vacuum Hose, Electrical Connectors And Electrical Cable

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-- Free up the electrical cable -5-.

-- Disconnect the vacuum hose -6- leading to the Evaporative Emission (EVAP) filter.

-- Disconnect the electrical connectors -1 - and pull the connectors out of the retainer.

Fig 19: Identifying Vacuum Line And Electrical Connectors

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-- Disconnect the connectors -2 through 4-.

-- Remove the vacuum line -5-.

-- Disconnect the coolant line from the intake manifold, when doing this, remove the bolts -arrows-.

Fig 20: Bracket Bolts

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-- Remove the intake manifold bracket by removing the mounting nut -1- and bolt -2-.

Fig 21: Identifying Intake Manifold Bracket Mounting Nut And Bolt

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-- Remove the oil filter.

WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

CAUTION:

Risk of contamination to the fuel system.

Note rules of cleanliness for working on the fuel injection system. Refer to CLEAN WORKING CONDITIONS .

-- Remove the fuel hose -1-.

Fig 22: Removing Fuel Hose

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-- Release the EVAP canister -B arrow-, remove it upward -A arrow- and lay it aside.

Fig 23: Locating Fuel Supply Line

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-- Disconnect the coolant hoses -arrows- and move them to the side.

Fig 24: Coolant Hoses

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-- Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Fig 25: Camshaft Adjustment Valve And Bolts

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-- Remove the bolts -arrows- and then the camshaft adjustment valve 1.

-- Remove the bolts -1 through 5- and the timing chain guard upper section.

Fig 26: Identifying Upper Timing Chain Cover - Tightening Sequence

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CAUTION:

The control valve has a left thread.

-- Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Fig 27: Identifying Assembly Tool T10352 To Remove Control Valve

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-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 28: Bearing Bracket Bolts

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-- Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

Fig 29: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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The notch on the vibration damper must line up with the arrow marking on the camshaft timing chain lower cover.

-- Mark the camshaft timing chain and the cylinder head -arrows- to match the marking on the chain sprockets -1- with a waterproof marker.

Fig 30: Marking Camshaft Timing Chain And Cylinder Head

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-- Remove the plug -arrow-.

Fig 31: Locating Plug

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-- Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner direction of -arrow 1-.

Fig 32: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011

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-- Turn the crankshaft opposite the engine direction of rotation -arrow direction 2- and secure it with a T40011.

NOTE:

The intake camshaft switches in the engine direction of rotation.

-- Remove the bolt -1- and guide the tensioning rail -2- downward.

Fig 33: Guide Tensioning Rail, Upper Guide Rai And Bolt

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-- Remove the upper guide track -3- by unlocking the latch with a screwdriver and pushing the guide track forward.

-- Remove camshaft timing chain from chain sprockets.

CAUTION:

Risk of damaging valves and piston crowns.

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.

-- Turn the sealing plug -arrows- counterclockwise 90° in the direction of the -arrow- and remove it.

Fig 34: Ball Head And Sealing Plug

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-- Remove the ball heads -1 through 2-.

-- Remove the cap.

-- Remove the bolts -arrows-.

Fig 35: Cylinder Head Loosening Sequence

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-- Remove the cylinder head bolts in sequence -1 to 5-.

NOTE:

To remove the cylinder head bolts, turn the camshaft with a wrench if necessary.

Make sure all wires and cables are disconnected!

Pay attention to the tension and guide tracks when lifting the cylinder head.

-- Remove the cylinder head.

-- Lay the cylinder head on a soft surface, such as foam.

Installing

For the correct tightening specifications, refer to CYLINDER HEAD OVERVIEW .

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.

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Risk of cylinder head seal leaking.

Carefully remove all grinding and sanding residue.
Only unpack new cylinder head gasket immediately prior to installation.
To prevent the cylinder head seal silicone layer and recessed area from being damaged, always handle seal with extreme care.

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 the bolts which are being tightened with an additional turn.

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

If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the camshaft housing.

The hose supports, air guide pipes and hoses must be free of oil and grease before installing.

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

To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.

-- Set cylinder head gasket in place.

Pay attention to centering pins in cylinder block -arrows-.

Fig 36: Cylinder Block Centering Pins
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Observe cylinder head seal location, identification: The part number must be visible from the intake side.

WARNING:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.

-- Set cylinder head in place.

-- Insert cylinder head bolts and tighten by hand.

NOTE:

In order to be able to turn the cylinder head bolts, the intake camshaft must be turned with a wrench.

-- Cylinder head tightening sequence, refer to Figure:

NOTE:

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

-- Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

Fig 37: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

NOTE:

The marked links of the camshaft timing chain must be positioned on the markings on the chain sprockets.

Fig 38: Marked Links Of Camshaft Timing Chain Must Be Positioned On Markings On Chain Sprockets

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-- Turn the intake camshaft in direction of -arrow- with the wrench and install the camshaft timing chain. The markings on the camshaft timing chain and on the cylinder head -arrows- must line up with the markings on the chain sprockets -1-.

-- Mount the bearing bracket and the bolts -arrows- hand-tight.

Fig 39: Bearing Bracket Bolts

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-- Remove the T40011.

-- Tighten the bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN OVERVIEW .

-- Install the control valve CAMSHAFT TIMING CHAIN OVERVIEW .

Further installation is performed in the reverse order of removal, thereby observing the following:

-- Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN COVER .

-- Change engine oil.

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

WARNING:

Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.