Removing and Installing Right Cylinder Head
Removing and installing right cylinder head
Note:
^ All hose connections are secured with clips.
^ Charge air system must be free of leaks.
^ Replace all seals and gaskets.
Removing
- Remove engine, Service and Repair
- Unplug connector from air recirculation valve -2-.
- Remove cover panel from right-hand cylinder head cover -arrows-.
- Disconnect hose -1-.
- Disconnect hose -2-.
- Unbolt upper section of intake pipe -3
Note: Plug lower section of intake pipe.
- Unplug connectors from injectors -2- (cylinder bank 4..6).
- Unplug connector for camshaft timing control -1- (cylinder bank 1..3).
- Unplug connectors from injectors -2- (cylinder bank 1..3).
- Unplug connectors from ignition coils -3- and move wiring harness clear (cylinder bank 1..3).
- Pull crankcase breather-4- off cylinder head cover (cylinder bank 1 ..3)
- Pull off hose -5- going to turbocharger intake side.
- Remove ignition coils.
- Unclip solenoid valve for charge pressure control -1-.
- Pull connector off EVAP valve -2-.
- Pull connector off throttle unit -1-.
- Pull connector off charge air sensor -2-.
- Pull off crankcase breather -3-.
- Pull connector off intake air temperature sender-4-.
- Pull connector -5- off Hall sender.
- Remove pressure pipes -1-.
Note: Watch position of retaining strips -2-.
- Remove tensioner -1- for ribbed belt.
- Remove toothed belt guards -2- (left and right).
- Remove toothed belt guard -3(center).
- Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
Note: Turn over the engine at the central bolt on the crankshaft.
- Check position of camshafts: larger holes in securing plates on camshaft sprockets must align opposite one another on inside. If not, turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
- TDC drilling in crankshaft must be visible (or able to be felt) in line with sealing plug hole.
- Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.
- Remove vibration damper on crankshaft.
Note: The central bolt does not have to be loosened to remove the vibration damper.
- Remove idler wheel for ribbed belt -arrows-.
- Remove toothed belt guard behind vibration damper-arrows-.
Note:
^ Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when refined.
^ The toothed belt tensioning element is oil damped and can therefore only be compressed slowly by applying constant pressure.
- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until tensioning lever-2 compresses tensioning element-3 sufficiently to enable a 2 mm dia. spring pin to be fitted in drilling and in plunger.
- Insert spring pin and release toothed belt tensioning roller.
^ Use spring pin from 2024 A.
- Insert camshaft clamp 3391 in securing plates of two camshafts.
- Loosen both camshaft bolts and unscrew approximately 5 turns.
- Take out camshaft clamp 3391.
- Pull off both camshaft sprockets with special tool T40001.
- Unbolt rear right toothed belt guard -arrows-.
- Detach intake manifold using special tool 3249.
- Unbolt water pipe -1- and pull toward rear.
- Detach line -arrow- from cylinder head.
- Remove turbocharger-arrows-.
- Unbolt cylinder head cover.
- Loosen and unscrew cylinder head bolts in opposite sequence to tightening sequence using special tool 3452 (Polidrive).
- Carefully lift off cylinder head.
Note: Use special tool 3452 together with a normal commercial 10 mm socket when removing and installing.
Installing
Note:
^ Do not allow any oil or coolant to remain in the blind holes for the cylinder head bolts in the cylinder block.
^ Install new cylinder head bolts.
^ Connecting vacuum hoses Diagrams
When installing a new cylinder head:
- Screw in centering pin for intake manifold.
The cylinder head supplied as a replacement part can be used on both sides (left or right). But a sealing cap (core plug) must be fitted in the front end of the cylinder head in each case.
- Coat outside circumference of sealing cap (core plug) with sealant AMV 188 001 02.
- Using drift VW 295, knock in sealing cap (core plug) until outside rim is flush with end of chamfer in cylinder head.
- Before fitting cylinder head in position, turn crankshaft and camshafts to TDC of No. 3 cylinder.
- Fit cylinder head gasket on dowel sleeves. Marking "oben" (top) or part number must face towards cylinder head.
- Fit cylinder head, insert cylinder head bolts and tighten finger-tight.
- Tighten cylinder head bolts in two stages in sequence shown, as follows:
^ Stage 1 = 60 Nm.
^ Stage 2 = turn a further 1/2 turn (180°) with a rigid wrench (turning 2 x 90° is also permissible).
It is not necessary to torque down cylinder head bolts again after repairs have been completed.
- Seal end points of joints between bearing caps and cylinder head.
- Before installing cylinder head cover and gasket, carefully apply a small quantity of sealant D 454 300 A2 at four end points of sealing surfaces on cylinder head -arrows-, using a small screwdriver.
Tightening torques