Valve Cover: Service and Repair

Cylinder Head Cover

Special tools, testers and auxiliary items required

• Spring Type Clip Pliers (VAS 5024 A)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Assembly Tool (T10118)

• Puller for Ignition Coil (T10095 A)

Removing

- Remove the ignition coils with power output stage. Refer to => [ Ignition Coils with Power Output Stages ] Service and Repair.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

• Seal the intake passages in the intake manifold and in the cylinder head with clean cloths.

- Remove the bolts - 1 and 2 - and the bracket - A -.






- Free up the wires on the rear of the cylinder head and remove the bracket bolts - arrows - and bracket - A - from the cylinder head cover.






- Remove the crankcase housing ventilation hose from the cylinder head cover.

- Loosen the cylinder head cover bolts - 17 through 1 - starting from the inside and working toward the outside.






- Remove the bolts and the cylinder head cover.

Installing






- Apply the sealant (D 454 300 A2) at the locations marked - arrows - on the cover.

- Install the cylinder head cover and tighten the bolts - 1 through 17 - evenly starting on the inside and working toward the outside.






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

• Replace the cylinder head cover if it is damaged or if there are leaks.

• First, bolt the intake manifold to the cylinder head. Then, tighten the bolts for the intake manifold support.

• Make sure the fuel hoses are secure.

- Fill with coolant, if necessary. Refer to => [ Coolant, Filling ] Coolant, Filling.

Tightening Specifications