Valve Cover: Service and Repair
Cylinder head cover, removing and installing
Special tools and equipment
^ T10095 Puller
^ VAG 1331 Torque wrench (5 50 Nm)
^ VAS 5024 Assembly tool for spring-type clips
^ Cable tie
Removing
CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: All cable ties which are opened or cut open during disassembly, must be replaced in the same position during installation
- Remove engine cover.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Disconnect connectors from ignition coils 1...6.
Note: Mark connector and component before pulling connector off.
- Unclip ignition coils wiring harness from wiring guide.
- Remove ignition coils with final output stage for cylinders 1 6 using puller T10095.
- Pull off crankcase breather connecting hose between cylinder head cover and intake hose on cylinder head cover.
- Remove intake hose between Mass Air Flow (MAP) sensor and throttle valve control module: Service and Repair
Note: Press buttons on hose couplings to do so.
- Pull 6-pin connector off throttle valve control module -arrow-.
- Open and close expansion tank cap to release pressure in cooling system.
- Pull coolant hoses off throttle valve control module and seal hose ends.
- Pull fuel supply hose -1- (with white marking) and fuel return hose -2- (with blue marking) off fuel rail and collect fuel that may leak out with a cloth.
WARNING: Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
- Seal lines to avoid contamination of fuel system.
- Observe rules for cleanliness, Refer to Powertrain Management, Fuel Delivery and Induction, Service and Repair
- Remove retaining frame on cylinder head for fuel lines and wiring harness -arrows-.
- Disconnect vacuum hoses -arrows- from intake manifold.
Note: Press buttons on hose couplings to do so.
- Remove rearmost bolt -1- for intake manifold support.
- Unclip pressure hose (between combi-valve and secondary air pump motor) and all other lines from retainers on intake manifold and cylinder head cover.
- Remove guide on cover for coolant hoses and wiring harness.
- Remove Ground connection on support of combi-valve.
- Disconnect vacuum hose from variable intake manifold change-over vacuum actuator.
- Remove two lateral intake manifold support bolts.
- Remove center, left and right insulation trays
- Disconnect connectors from thermal switch and radiator fan.
- Removing front bumper:
- Bring lock carrier into service position, please refer to: Vehicle /Body and Frame /Radiator support/ Service and repair.
[1][2]Procedures
- Unscrew dipstick guide tube from intake manifold.
- Remove intake manifold securing bolts and remove intake manifold together with throttle valve control module.
- Remove intake manifold and place on a suitable surface so that vacuum actuator is not damaged.
Note: Seal the intake ports in the intake manifold or in the cylinder head with a clean cloth.
- Remove cylinder head cover.
Installing
Install in reverse sequence; note the following points:
Note:
^ Replace cylinder head cover if damaged or leaking.
^ First bolt intake manifold to cylinder head. Then tighten both bolts of the manifold support.
^ Ensure tight fit of fuel hoses.
- If necessary replenish coolant.
- Check DTC memory:
Refer to Powertrain Management
- Adapting engine control module to throttle valve control module
- Perform work sequence "Procedure after interrupting voltage supply"
- Read readiness code:
Refer to Powertrain Management
- If DTC memory has been erased or engine control module separated from permanent positive supply, readiness code must be generated again:
Refer to Powertrain Management
Torque settings