Replacement

NOTE: During service procedures, refer to the illustration above and the information below

Removal

NOTE:
^ When installing an exchange cylinder head (with camshaft), the contact surfaces between hydraulic lifter and cam must be oiled after installation.
^ The plastic protectors (fitted to protect the open valves) should only be removed just before installing the cylinder head.
^ If the cylinder head is replaced, completely replace the engine coolant

1 Intake manifold
- Removing and installing refer to Replacement. Service and Repair
- First tighten to lower intake manifold, then to the two rear supports (items 7 and 3)
- Disassembly and assembly refer to Disassembly/Assembly. Service and Repair
2 Bolt
- Tighten to: 25 Nm (18 ft lb)
3 Right rear support
- Between intake manifold and cylinder head cover
4 Throttle Valve Control Module
- Heated by coolant
- Removing and installing: refer to Powertrain Management
5 Connection
- Removing and installing: refer to Powertrain Management
6 Exhaust Gas Recirculation (EGR) valve
- Refer to Powertrain Management
7 Rear left support between intake manifold and cylinder head
8 Cap
9 Gasket
- Replace if damaged
10 Vacuum hose
- To EGR valve/intake manifold junction piece
- Refer to Powertrain Management.
11 Oil filler pipe
12 Nut
- Tighten to: 10 Nm (7 ft lb)
13 O-ring
- Replace if damaged
14 Cylinder head cover
- Removing and installing, refer to Replacement. Service and Repair
- Replace if damaged or leaking
15 O-ring
- Always Replace
- Coat with oil before assembling, insert in camshaft sprocket cover (item 16)
16 Camshaft sprocket cover
- Can be removed and installed with cylinder head installed
- Coat sealing surfaces with AMV 188 001 02
- If only the camshaft sprocket cover has been removed; prepare cylinder head gasket for assembly, refer to Fig. 2 below
17 Spacer ring
18 O-ring
- Always Replace
- Oil before installing
19 Camshaft Position sensor -G40-
- Checking, refer to Powertrain Management
20 Bracket
- For -G98- EGR Temperature sensor, 2- pin connector
21 Seal
- Always Replace
22 Chain tensioner
- Tighten to: 30 Nm (22 ft lb)
- For double chain
- Bleed before installing, refer to Fig. 2 of part 2 of Disassembly/Assembly To Major Components. Procedures

CAUTION: Only turn engine when the chain tensioner is installed

23 Ground connection
24 Bracket
25 Ignition Coil -N152-
- Checking, refer to Powertrain Management
26 Bracket
- For fuel injector connectors (item 35)
27 Thermostat housing
- Disassembly and assembly, refer to Cooling System.
28 O-ring
- Always Replace
29 Cylinder head gasket
- Always Replace
- If replaced, completely replace the engine coolant
30 Cylinder head
- Check for distortion refer to Fig. 1 below
- Installing: refer to "Installation" below
- If replaced, completely replace the engine coolant
- Note sequence when loosening and tightening
- Refer to "Installation" below
31 Cylinder head bolt
- Always Replace
- Note sequence when loosening and tightening
- Refer to "Installation" below
32 Lower intake manifold gasket
- Always Replace
- Note installed position
33 Ribbed belt tensioner
- Ribbed belts, removing and installing: refer to Replacement. Service and Repair
34 Positive Crankcase Ventilation valve
- Arrow on valve points toward intake hose
- Refer to Powertrain Management,
35 Connector
- For injectors N30, N31, N32, N33, N83 and N84
- Mounted to bracket (item 26)
36 Retainer
- For Secondary Air Injection pump motor
- Refer to Powertrain Management.

Procedures





Fig. 1 Cylinder Head, Checking For Distortion
Special tools, testers and auxiliary items
- Feeler gauge set

- Maximum permissible distortion: 0.10 mm





Fig. 2 Cylinder Head Gasket, Preparing For Assembly
Special tools, testers and auxiliary items
- AMV 188 001 02 or equivalent sealant

- Remove old sealant from 3 mm holes in the cylinder head gasket -arrows-
- Fill 3 mm holes in the cylinder head gasket using sealant AMV 188 001 02

NOTE: When the cylinder head is installed, the holes are only half visible.

Installation
Special tools, testers and auxiliary items
- VAG 1332 Torque wrench 40 to 200 Nm (30 to 148 ft lb)
- 3268 Crankshaft setting bar

Work Sequence





- Set crankshaft to TDC cyl. 1 marks -arrow- by turning crankshaft (via vibration damper mounting bolt) in direction of engine rotation





- Position camshafts using 3268 camshaft jig

NOTE: This orientation is only possible every 2nd TDC position.





- Install cylinder head gasket

- Note position of centering sleeves (in block holes 12, 20)

- Install cylinder head
- Insert cylinder head bolts and tighten by hand
- Tighten cylinder head using four stage sequence as follows:
Tighten initially using torque wrench
Stage I: 40 Nm (30 ft lb)
Stage II: 60 Nm (44 ft lb)
Turn further using ordinary wrench
Stage III: 1/4 turn (90°) additional
Stage IV: 1/4 turn (90°) additional

NOTE:
^ Loosening cylinder head: reverse sequence
^ Torquing cylinder head after repairs is not necessary