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

• To perform the procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand.

- With the ignition turned off, disconnect the battery ground cable.

- All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.

- Bring the lock carrier into the service position. Refer to Procedures

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

- Remove the intake manifold, refer to one of the following:

With a one piece intake manifold, refer to => [ Intake Manifold ] Intake Manifold

With a two piece intake manifold, refer to => [ Upper Intake Manifold ] Upper Intake Manifold

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

- Disconnect all other electrical wires from the cylinder head cover and set them to the side.

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





- Remove the bolts and remove the cylinder head cover.

Installing

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





- Install the cylinder head cover and tighten the bolts uniformly, starting from the inside and working toward the outside- 1 through 17 -.





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 install the intake manifold to the cylinder head. Then tighten both bolts for the intake manifold support.

• Ensure the fuel hoses are securely seated.

- Fill the cooling system, if necessary. Refer to => [ Draining and Filling ] Draining and Filling.

Tightening Specifications