Cylinder Head, Removing And Installing

WARNING: This page is about a different car, the 2023 Volkswagen Atlas. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools & Workshop Equipment

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Special tools and workshop equipment required

Camshaft Bar:T10068A
Shop Crane - Drip Tray:VAS 6208
Shop Crane:VAS 6100
Lifting Tackle:3033
Spring Clip Pliers:VAS 6499
Puller - Ignition Coil:T10095A
Applicator Gun:VAS 6966

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Not illustrated:

Special tools and workshop equipment required

Torque Wrench, 6-50Nm:VAG 1331A
Torque Wrench, 40-200Nm:V.A.G 1332A
Sealant:D 176 501 A1
Locking Fluid:D 197 300 A2

Requirements

The engine must be no more than warm to touch.

Removing

NOTE:

Any cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

To prevent damage to the removed components, use the Storage Rack:V.A.G 1698A for storage.

-- Disconnect the battery ground cable when the ignition is switched off.

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

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

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CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Disconnect the fuel supply line -1-. Refer to Connector Couplings, Disconnecting .

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

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

-- Remove the intake manifold lower section and disconnect all connectors. Refer to INTAKE MANIFOLD LOWER SECTION WITH FUEL RAIL, REMOVING AND INSTALLING .

-- Unscrew the heat shield and the intake manifold support from the cylinder head.

-- Remove the front exhaust pipes from the exhaust manifolds.

-- Remove the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Pull out the pump plunger OVERVIEW - VALVETRAIN => List Item:Pump Plunger.

-- Remove the retainer for the coolant vales from the cylinder head. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .

-- Disconnect the following connectors.

Fig 2: Camshaft Adjustment Valve & Camshaft Position (CMP) Sensor

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Camshaft Position Sensor -G40-
Camshaft Adjustment Valve 1 -N205-
Camshaft Position Sensor 3 -G300-
Exhaust Camshaft Adjustment Valve 1 -N318-

-- Remove all remaining electrical wires necessary from the cylinder head and set aside.

-- Remove the coolant hose from the connection on the heater core OVERVIEW - CYLINDER HEAD => List Item:Connection.

-- Remove the upper and lower coolant pipes on the cover from the cylinder head.

-- Remove the vacuum pump. Refer to VACUUM PUMP, REMOVING AND INSTALLING .

-- Remove the bolts -1- through -3- from the coolant connections.

Fig 3: Identifying Three Mounting Bolts On Coolant Connection

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-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Turn the crankshaft in the direction of engine rotation to cylinder 1 TDC.

Fig 4: Identifying Cylinder 1 At Top Dead Center (TDC) Mark

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Cams -A- of cylinder 1 must face each other.

Fig 5: Camshaft Lobes For Cylinder Facing Each Other

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-- Remove the chain tensioner for the camshaft timing chain -arrow-.

Fig 6: Chain Tensioner Bolt Camshaft Roller Chain

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-- Unscrew both retaining bolts -1- from the sealing flange and then unscrew all retaining bolts -arrows- from the cover.

Fig 7: Identifying Sealing Flange And Cover Bolts

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-- Remove the cover.

NOTE:

Counterhold the camshaft with a 27 mm open end wrench -arrow-. The Camshaft Bar:T10068 A must not be inserted when tightening or loosening the camshaft adjuster.

Fig 8: Counter-Holding At Camshaft Using Wrench

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-- Unscrew the bolts -1- and -2- and then remove the guide rail -3-.

Fig 9: Camshaft Adjuster Mounting Bolts And Bolts Of Glide Track

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NOTE:

The timing chain is held by the lower timing chain cover on the oil pump chain sprocket. The timing chain cannot skip.

-- Remove the camshaft adjuster from the camshafts.

-- Remove the timing chain from the high pressure pump chain sprocket.

-- Remove the four bolts -arrows- from the timing chain cover and pull the control housing off the camshafts.

Fig 10: Identifying Control Housing And Bolts

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NOTE:

Do not turn the crankshaft from the TDC point after loosening the timing chain.

-- Cover the camshafts -arrows- with strips of paper and wrap the ends with adhesive tape.

Fig 11: Covering Camshafts With Clean Paper Strips And Wraping Ends With Adhesive Tape

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-- Loosen and remove the cylinder head bolts in the sequence shown starting from outside working toward inside.

Fig 12: Cylinder Head Loosening Sequence

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-- Attach the Lifting Tackle:3033 as shown and carefully lift the cylinder head using the Shop Crane:VAS 6100 .

Fig 13: Hooking Engine Sling 3033 Onto Engine And Onto Workshop Crane VAS 6100

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Vibration damper side: item 3

Drive plate side: item 11

NOTE:

The Lifting Tackle:3033 items marked 1 through 12 face toward the drive plate side.

Threaded spindles are set in length according to necessity.

-- Carefully lift the cylinder head off.

-- Stuff clean cloths into cylinder so that no dirt or grinding residue can get between cylinder wall and piston.

-- Do not allow dirt or grinding residue to get into coolant either.

-- Carefully clean the sealing surfaces on the cylinder head and cylinder block. Make sure that no long grooves or scratches result (do not use sandpaper with grit below "100").

-- Clean all threaded holes for the cylinder head bolts.

-- Check the cylinder head for distortion. Refer to Figure.

Installing:

Do not use any sanding materials (sandpaper, sand stone sanding pads, sanding strips, or abrasive cloths etc.).
May not be applied on sealing surfaces.
The dark discoloration does not need to be removed.

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When removing the sealant residue pay attention that no loosened sealant residue gets into the channel to the engine.
Pay attention to the neighboring work stations cleanliness and that no there is no sanding from above.
The use of unpermitted sanding materials can cause subsequent damage, such as turbocharger damage, connecting rod bearing, etc.

-- Carefully remove metal particles, grinding residue and cleaning cloths.

-- Check the cylinder bore for damage and wear. Refer to Checking the cylinder bore: .

NOTE:

Note the following, when checking the cylinder bore:

The marking on the vibration damper must align to the marking -arrows- on the sealing flange.

Fig 14: Identifying Cylinder 1 At Top Dead Center (TDC) Mark

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Turn the crankshaft by 180° (¹ /₂ turn) opposite the direction of engine rotation. While this, have a second technician keep the camshaft timing chain on tension and guide it by hand.

Perform the checks when the respective cylinder is at the bottom dead center (BDC).

Turn back the crankshaft by 180° (¹ /₂ turn) in direction of engine rotation. While this, have a second technician keep the camshaft timing chain on tension and guide it by hand.

-- Check the position again:

Fig 15: Identifying Cylinder 1 At Top Dead Center (TDC) Mark

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The marking on the vibration damper must align to the marking -arrows- on the sealing flange.

If the piston for cylinder 1 is not at TDC:

-- Turn the crankshaft in the direction of engine rotation to TDC cylinder 1 -arrow- while a second technician guides the camshaft timing chain by hand and keeps it on tension.

-- Make sure that alignment bushings are inserted in bore 12 and 20 in cylinder block.

Fig 16: Cylinder Head Tightening Sequence

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-- Apply a 2 mm bead of Sealant:D 176 501 A1 on the joint between the cylinder block/sealing flange as shown -arrows-.

Fig 17: Identifying Sealant Location For Cylinder Block/Sealing Flange

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NOTE:

Only unpack the new cylinder head gasket immediately prior to installation.

Be very careful when handling the new gasket. Damaging will lead to leaks.

-- Install the new cylinder head gasket immediately. The text (part number) must be visible.

-- Additionally fill both 3 mm holes on the sealant bead with Sealant:D 176 501 A1 .

-- Move the camshafts inside the cylinder head to cylinder 1 TDC.

Cams -A- of cylinder 1 must face each other.

Fig 18: Camshaft Lobes For Cylinder Facing Each Other

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-- The Camshaft Bar Camshaft Bar:T10068A must engage in both shaft grooves.

Fig 19: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

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-- Install the cylinder head.

-- Apply Locking Fluid:D 197 300 A2 to each cylinder head bolt in the head contact surface area -arrow- and insert the bolts.

Fig 20: Applying Liquid Locking Fluid To Cylinder Head Bolt

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NOTE:

The Locking Fluid works as a fine seal over the cylinder head bolt.

The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

-- Tighten the cylinder head bolt from the inside outward. Refer to Figure.

-- Lubricate the sealing rings of the camshafts and install the control housing. The timing chain must be placed over the camshaft adjustment valves.

Fig 21: Identifying Control Housing And Bolts

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-- Secure the high pressure pump drive pinion in position with the Adjustment Tool:T10363 . The marking -A- on the on high pressure pump drive pinion must be at the top.

Fig 22: Securing Position Of Drive Pinion For High Pressure Pump Using Adjustment Tool T10363

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-- Install the timing chain on the high pressure pump chain sprocket so that it is >>taut<< and then screw on the guide rail -arrow-.

Fig 23: Identifying Guide Rail Bolt

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Further assembly is performed in the reverse order of the removal.

-- Install the camshaft adjuster with camshaft drive timing chain. Refer to CAMSHAFT ADJUSTER, REMOVING AND INSTALLING .

-- Install the cylinder head cover. Refer to CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION WITH FUEL RAIL, REMOVING AND INSTALLING .

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

-- Fill with new coolant. Refer to COOLANT, DRAINING AND FILLING .

Tightening Specifications

Refer to OVERVIEW - CYLINDER HEAD
Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM