Removing and installing cylinder head Page 1 of 25

Removing and installing cylinder head

Special tools and workshop equipment required

Support bracket -10 - 222 A-

Adapter -10 - 222 A /13-

Diesel injection pump locking pin -3359-

Hose clip pliers -V.A.G 1921-

Drip tray for workshop hoist -VAS 6208-

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Bracket -T10014-

Crankshaft stop -T10050-

Counterhold tool -T10051-

Puller -T10052-

Adapter -T40093/6- from engine support bracket (supplementary set) -T40093-

Removing

Caution
Observe notes on procedure for disconnecting the battery
→ Rep. Gr.27.

Note
The battery is located in the luggage compartment panel.
– Switch off ignition and remove ignition key.

– Disconnect earth cable -arrow- at battery.

– Remove bonnet → Chapter.
– Drain off coolant → Chapter.
– Remove catalytic converter → Chapter.

– Remove poly V-belt → Chapter.

– Unbolt heat shield for drive shaft (left-side)

-arrows-.

Vehicles with engine code letters AMF:

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– Detach air intake hose -6- from

turbocharger.
– Detach charge pressure control hose -5-
at turbocharger and at vacuum unit for
charge pressure control.

– Disconnect breather hose -4-.

– Unscrew bolts -3- and detach air pipe
from turbocharger.

Note

The air pipe remains in installation
position and is detached upwards at a
later stage.

Disregard -items 1 and 2-.

Vehicles with engine code letters ATL,

BHC:

– Detach vacuum hose -1- from vacuum

unit for charge pressure control and
move it clear.

– Unscrew bolts -2- and detach air pipe

from turbocharger.

Note
The air pipe remains in installation position
and is detached upwards at a later stage.
– Detach air intake hose -3- from
turbocharger.

All models:

– Unbolt bracket for air pipe from sump -

arrows-.

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– Remove air intake hose -2- (right-side) from

charge air cooler.

Note
Disregard -item 1-.

– Unplug electrical connector at oil level

and oil temperature sender -G266-.
– Move wiring clear.

Note
Depending on version, oil level and oil
temperature sender -G266- can be located
at front of sump.

– If fitted, unclip bracket -1-.

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– Take off engine cover panel -arrows-.

– Remove noise insulation beneath cover.

– Lever off caps -3 and 4- on two-piece

windscreen wiper arm with a screwdriver.

– Slacken nuts on two-piece windscreen

wiper arm a few turns.

– Release arms -1 and 2- one after the

other by tilting them slightly on the wiper
shafts.

– Remove nuts completely and take off

two-piece windscreen wiper arm.

Note
Use puller (commercially available) to
remove wiper arm if necessary.

– Disconnect washer fluid hose -3-.

– If fitted, unplug electrical connectors -4 and
5- for heated washer jets.
– Open hose clip -6- using hose clip pliers -
V.A.G 1921- and detach water drain hose
from cowl panel grille.
– Pull off rubber seal -1- on cowl panel grille.
– Disconnect cowl panel grille -2-.

– Unscrew nuts and bolts -arrows-.

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– Pull fresh air duct forwards and remove by

turning it to right side of vehicle.

Vehicles with engine code letters AMF:

– Detach air hose -2- at mechanical
exhaust recirculation valve.
– Disconnect vacuum hose -3- at
mechanical exhaust gas recirculation
valve.
– Disconnect vacuum hose -4- from
vacuum unit for intake manifold flap.

Note
Disregard -item 1-.

– Remove air intake hose -2- from charge air

cooler.

Note
Disregard -item 1-.

Vehicles with engine code letters ATL:

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– Remove air hose -3- from intake manifold

flap motor -V157- by lifting retaining clip -2-
slightly.
– Disconnect vacuum hose -1- at mechanical
exhaust gas recirculation valve.

– Remove air intake hose -2- from charge air

cooler.
– Unplug electrical connector at charge
pressure sender -G31--item 1-.

All models:

WARNING
Risk of scalding - the temperature of the
fuel and the fuel lines can be as high as
100 °C.

Allow the fuel to cool down before
disconnecting the lines.

Wear protective gloves.

Wear safety goggles.

– Mark fuel supply pipe -2- and fuel return

pipe -1-.
– Move fuel lines clear.

– Detach air intake hose -1- at air mass

meter -G70-.

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– Unplug electrical connector -3- at air mass

meter -G70-.
– Remove nut -2-.
– Disconnect crankcase breather hose -4- at
cylinder head cover.

– Pull air pipe out slightly together with air

mass meter -G70-.

– Detach electrical connector -arrow- at

heater element for crankcase breather -
N79- (if fitted).
– Remove air pipe.

Vehicles with engine code letters ATL:

– Detach electrical connector -arrow- at
intake manifold flap motor -V157-.
– Move wiring clear.

All models:

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– Disconnect drain hose -2-.

– Remove water collector -1-.

– Remove top left coolant hose -items 1

and 2-.

– Mark coolant supply hose -1- and coolant

return hose -2- going to heat exchanger
and disconnect coolant hoses at bulkhead.

Vehicles with engine code letters ATL,

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Removing and installing cylinder head Page 10 of 25

BHC:
– Unplug vacuum hose -1-.
All models:
– Detach vacuum hose -2- (going to brake
servo) from tandem pump.

– Move vacuum hoses clear.

– Unplug electrical connectors -2- on glow

plugs.
– Pull retaining tab and loosen knurled nut -
3- at main connector for unit injectors.
– Unplug connector for Hall sender -G40--
item 4-.
– Unplug electrical connector -7- at fuel
temperature sender -G81-.

Note
Disregard -items 1, 5 and 6-.

– Detach oil supply pipe -2- going to

turbocharger at oil filter bracket.
– Remove bracket for oil supply pipe -3-.

Note
Disregard -item 1-.

– Unplug electrical connector -arrow- at

coolant temperature sender -G62-.

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– Unbolt bracket for wiring harness from

coolant connection -arrow-.
– Move electrical wiring harness clear.

– Detach top coolant hose from coolant

expansion tank -top arrow- and move
clear.

– Unscrew poly V-belt tensioner -arrows-.

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– Remove toothed belt cover (top section) -

arrows-.

– Unbolt vibration damper; counterhold on

centre bolt with ring spanner.

– Unbolt toothed belt cover (centre and

bottom) -arrows-.

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– Remove bottom bolt -1- for engine support.

Note
Bolts -2 and 3- do not have to be removed at
this stage.

Vehicles with engine code letters ATL,

BHC:
– Remove bolts -1 and 2- and detach
support for turbocharger.

All models:
– Remove oil return pipe -3- at cylinder
block.

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– Slacken bolt -1- approx. 3 turns.

– Remove nut -2-.
– Unbolt oil supply pipe -3- from
turbocharger and move clear to one side.

– Set up support bracket -10 - 222 A- with

adapters -10 - 222 A /13- and adapter -
T40093/6- on wing panel flanges.

Caution
At the same time, engage adapter -10 -
222 A /13- in mountings for bonnet -
arrow-.

 Remove clamping bolt in adapter -

T40093/6-.
 Adapter -T40093/6- is fitted with its arm
pointing upwards.
– Attach hook on spindle -10 - 222 A /11--
item A- to engine lifting eye.
– Take up weight of engine using spindle -
item A- (but do not raise engine).

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Note
The second spindle -item B- (right-side) is
not used at this stage.

Vehicles with cover for engine mounting

– Remove cover for engine mounting by
unscrewing bolts -1 and 2-.

– Remove bolts -1 and 3- and detach

support arm with engine mounting -2-.

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Vehicles without cover for engine

mounting

Note
Do not loosen nut -3- unless renewing engine
mounting.
– Remove bolts -1 and 2- and detach
support arm with engine mounting.

All models:
– Remove top bolts -2 and 3- and detach
engine support.

Caution
The engine must only be turned at the
crankshaft, in the direction of normal
engine rotation (clockwise).

Note
Turn over the engine at the central bolt on the
crankshaft.

– Turn the crankshaft to “TDC”.

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 The space between the two lugs on sender

wheel of camshaft must align with marking
“3Z” on toothed belt cover (rear) -arrows-.
– Lock hub on camshaft with locking pin -
3359-.
– Lock crankshaft sprocket with crankshaft
stop -T10050-.

Note
The crankshaft stop can only be pushed onto
the sprocket from the front face of the teeth.
 The markings on the toothed belt sprocket
and the crankshaft stop -T10050- must
align. The pin of the crankshaft stop -
T10050- must engage in the aperture in
the sealing flange.
– Remove toothed belt: toothed belt drive
with hydraulically damped tensioning roller
→ Chapter, toothed belt drive with friction-
damped tensioning roller → Chapter.

– Unscrew bolts -1- and detach camshaft

sprocket from hub.

– Loosen bolt -1- for hub; use counterhold

tool -T10051-.
– Then unscrew bolt approx. 2 turns.

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– Fit puller -T10052- on hub and fit bolts -1-.

– Remove hub from camshaft by screwing in
bolt -2- while counterholding at hexagon
flats (30 mm) of puller.
– Detach hub from taper of camshaft.

– Remove toothed belt tensioning roller.

– Remove bolts -2 ... 4-.
– Unscrew stud -1- using two M8 locknuts.

– Screw in bracket -T10014- into threaded

hole above coolant pump.

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– Attach free hook of spindle -10 - 222 A /11-

-item B- to bracket -T10014-.

– Lift engine via spindle -B- until spindle -

A- has no more load.

– Unhook spindle -A- and move clear to

one side.

– Remove cylinder head cover bolts in the

sequence -11 ... 1-.

Note
Disregard -arrows-.
– Detach bracket with fuel pipes.
– Remove cylinder head cover.

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– Loosen cylinder head bolts in the

sequence: -1 ... 8-.

– Carefully lift off the cylinder head with the

assistance of a 2nd mechanic.
– Lay cylinder head aside on a clean surface
with the combustion chamber side facing
upwards.

Installing

Note

Renew the cylinder head bolts.

Renew self-locking nuts and bolts.

Renew bolts which are tightened to a
specified angle as well as oil seals and
gaskets.

If repairing, carefully remove any remaining
gasket material from the cylinder head and
cylinder block. Ensure that no long scores
or scratches are made on the surfaces.

Carefully remove any remaining emery and
abrasive material.

No oil or coolant must be allowed to remain
in the blind holes for the cylinder head
bolts in the cylinder block.

Do not remove new cylinder head gasket
from packaging until it is ready to be fitted.

Handle gasket very carefully. Damage to
the silicone coating or the indented area
will lead to leaks.

Cylinder heads with cracks between the
valve seats may be used without reducing
engine life, provided the cracks are small
and not more than 0.5 mm wide.

The cylinder heads of diesel engines must
not be machined.

When installing a replacement cylinder

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head with fitted camshaft, the contact

surfaces between hydraulic tappets and
cam running surfaces must be oiled after
installing the cylinder head.

The plastic protectors fitted to protect the
open valves should not be removed until
the cylinder head is ready to be fitted.

Secure all hose connections with the
correct type of hose clips (same as original
equipment) → Parts catalogue.

After fitting a new cylinder head or cylinder
head gasket, change the coolant and
engine oil.

After working on the valve gear, turn the
engine carefully at least 2 rotations to
ensure that none of the valves make
contact when the starter is operated.
– Check whether the camshaft and the
crankshaft are positioned at “TDC”:
 The cams for cylinder 1 must point upwards
evenly on camshaft -arrows-.

 The crankshaft sprocket must be locked

with the crankshaft stop -T10050-.
 The markings on the toothed belt sprocket
and the crankshaft stop -arrow- must align.
The pin of the crankshaft stop must engage
in the aperture in the sealing flange.

– Note identification markings on cylinder

head gasket.
1 - Part No.

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2 - Production code (can be disregarded)

3 - Holes

Note

If the cylinder head gasket or cylinder head
is renewed, be sure to install a gasket with
the same identification.

If parts of the crankshaft drive have been
renewed, the new cylinder head gasket
must be selected by measuring the piston
projection at “TDC” → Chapter.
– Fit cylinder head gasket.

 Note position of centring sleeves in

cylinder block.
 Check installation position of cylinder head
gasket: the word “oben” (top) or the Part
No. should face towards the cylinder head.
– Fit the cylinder head.
– Check that all washers for cylinder head
bolts are fitted in cylinder head.

– Insert new cylinder head bolts and tighten

finger-tight.

– Tighten cylinder head bolts in 4 stages in

the sequence indicated:
1. Tighten with torque wrench to 40 Nm.

2. Tighten with torque wrench to 60 Nm.

3. Turn 90° ( 1/4 turn) further using a rigid
wrench.

4. Turn 90° ( 1/4 turn) further using a rigid

wrench.

Note
Cylinder head bolts do not have to be torqued
down again later after repair work.

– Apply locking fluid to bolts -2 ... 4- and

tighten; for locking fluid refer to → Parts
catalogue.
– Tighten stud -1- using two M8 locknuts.

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– Attach hub to camshaft.

– Tighten securing bolt -1- (use counterhold -
T10051-).

– Push camshaft sprocket onto hub.

 Toothed segment -arrow- of camshaft
sprocket must be at top.
– Screw in bolts -1- finger-tight.
– Lock hub on camshaft with locking pin -
3359-.
Remaining installation steps are carried out in
reverse sequence; note the following:
– Install cylinder head cover → Chapter.
– Install toothed belt (adjust valve timing):
toothed belt drive with hydraulically
damped tensioning roller → Anchor,
toothed belt drive with friction-damped
tensioning roller → Anchor.

Note

Follow all instructions for removing and

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installing toothed belt.

Hose connections and hoses for charge air
system must be free of oil and grease
before assembly. Do NOT use lubricant.

– Install vibration damper → Chapter.

– Install poly V-belt → Chapter.

– Install engine mounting with support arm

→ Chapter or → Chapter.
– Install catalytic converter → Chapter.
– Install air pipes/hoses with plug-in
connectors → Chapter.
– Electrical connections and routing
→ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Observe notes on procedures required
after connecting battery → Rep. Gr.27.
– Install windscreen wiper arm → Rep.
Gr.92.
– Change engine oil → Booklet809.
– Fill cooling system with fresh coolant
→ Chapter.
Tightening torques

Component Nm
Hall sender -G40- to cylinder head 10 1)
Rear toothed belt cover to M6 10 1)
cylinder head
M8 20 1)
Stud to cylinder head 15
Hub to camshaft 100
Engine support to cylinder block 45
Oil supply pipe to: Oil filter bracket 22
Turbocharger 22
Oil return pipe to: Turbocharger 15
Cylinder block 30
Support for turbocharger Turbocharger 20
to:
Cylinder block 25
Bracket for wiring harness to coolant hose/pipe 10
connection
Bracket for oil supply pipe to coolant hose/pipe 10
connection
Air pipe to: Turbocharger 8
Sump 8
Drive shaft heat shield to cylinder block 33
Engine cover panel to bracket 5.5

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 1) Install using locking fluid; refer to → Parts catalogue.

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