Valve Cover: Service and Repair
Cylinder Head Cover
Special tools, testers and auxiliary items required
• Locking Pin (T10060 A)
• Ignition Coil Puller (T10095 A)
• Assembly Tool (T10118)
Removing
Observe safety precautions when disconnecting the battery.
- Remove tool formed insert under luggage compartment floor covering.
- Remove cover - arrow - for battery compartment
- Remove formed insert from over the battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Remove center noise insulation fasteners - 1 to 3 -.
- Remove right noise insulation fasteners - 1 to 3 -.
- If equipped, remove vacuum hose - 2 - to air guide hose.
- Disconnect air guide hose - 1 - at throttle valve control module (J338).
- Disconnect mass air flow (MAF) sensor (G70) electrical connector - 3 -.
- Remove upper section of air filter housing - arrows -.
- Remove filter element.
- Pull off air guide cover - 1 -, disengage clips sideways to do so.
- Unclip air duct - 2 -.
- Remove lower section of air duct - arrows -.
- Remove lower section of air filter housing - arrows -.
- Disconnect secondary air hose at position indicated by - arrow -.
- Free up air hose to Secondary Air Injection (AIR) pump.
- Disconnect the connectors - 2 - and - 3 -.
- Disconnect crankcase ventilation hose - 1 -.
- Remove throttle valve control module (J338) from intake manifold - arrows -.
- Disconnect electrical harness connectors to ignition coils, to do so attach (T10118) on release button - arrow - and carefully disconnect harness connector.
- Attach (T10095 A) on ignition coils - arrow - as depicted in the illustration and pull out ignition coils in succession.
- Remove electrical wiring guide from intake manifold and lay aside.
• Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap - 1 - and slide release button - 2 - to the rear.
- Remove rear vacuum hoses - 2 to 5 - at intake manifold.
• Ignore - 1 -.
- Remove wiring connection from intake manifold - arrows - and lay back with hoses connected.
- Remove intake manifold bolts - arrows -.
- Remove top mounting bolts for fan shroud - top arrows -.
- Remove oil dipstick.
• Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.
- Swing tensioning device in direction of - arrow - to relieve tension on the ribbed belt and then lock it in place using the (T10060 A).
- Remove ribbed belt.
- Free up coolant hose at bottom on fan shroud.
- Disconnect electrical harness connector - 3 - at secondary air injection (AIR) pump motor (V101).
- Free up cable.
- On vehicles with DSG transmission, remove coolant pipe bracket - 2 - to transmission oil cooler.
- Remove bolts - 1 -.
- Loosen bolt - 4 - and remove Secondary Air Injection (AIR) pump with bracket.
- Disconnect electrical harness connectors - 1 - for coolant fans at bottom on fan shroud.
- Remove mounting bolts for fan shroud at bottom - bottom arrows -.
- Pull out fan shroud downward with both fans.
- Disconnect electrical harness connector - 1 - for A/C clutch on A/C compressor and free up electrical wire.
The air conditioning refrigerant circuit must not be opened.
- Remove bolts - arrow - for A/C compressor.
- Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.
- Remove electrical wire - 1 - on generator.
- Separate the electrical connector - 2 -.
• Ignore - 3 -.
- Remove upper idler roller - 1 -.
- Remove mounting bolts - 2 - and - 3 - for generator.
• Generator can be removed from bracket only with the upper mounting bolt still installed.
- Remove generator with electrical wiring connected from accessory assembly bracket.
- Remove generator downward and to the left.
- Disconnect electrical harness connector - arrow - at after-run coolant pump (V51).
- Remove bolts - 1 to 5 - and remove accessory assembly bracket.
- Pull after-run coolant pump (V51), with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.
• Coolant pump remains on the engine with coolant hoses connected.
- Disengage for engine speed (RPM) sensor (G28) connector - arrow - from bracket on oil dipstick guide tube.
- Remove bolt - 3 - and remove oil dipstick guide tube - 2 -.
- Remove bolt - 4 - and remove vacuum reservoir - 1 - from intake manifold.
- Lay vacuum reservoir aside with lines connected.
- Remove bolts - arrows - at front of intake manifold.
- Remove vacuum line - arrow - at variable intake manifold actuator.
• Ignore - 1 - and - 2 -.
- Protect intake manifold from damage with a clean cloth - 1 -.
- Swing intake manifold forward - arrow 1 - and then pull slightly to left - arrow 2 -.
• Seal intake channel in cylinder head with clean cloth or foam pieces so that no small parts can fall in.
- Remove right fuel line bracket on cylinder head cover.
- Remove left electrical line bracket from timing chain cover.
- Loosen cylinder head cover bolts in sequence - 11 to 1 -.
Installing
• Tightening specifications, refer to => [ Cylinder Head Component Overview ] Cylinder Head Component Overview.
Installation is in reverse order of removal, note the following:
• Replace cylinder head cover seals and screws if damaged.
- Tighten cylinder head cover bolts in sequence - 1 to 11 -.
- Install intake manifold.