Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip Tray (VAS 6208)
• Retainer (3036)
• Puller (T40001)
• Ignition Coil Puller (T40039)
• Hose Clip Pliers (V.A.G 1921)
• Engine Support Bridge (10 - 222 A)
• Shackle (1 Set=2 Pieces) (10 - 222 A /12)
• Locking Pin (T10060A)
• Toothed Belt Tensioner (T10020)
• Polydrive Bit and Drive Socket (T10070)
• Engine Bung Set (VAS 6122)
Removing
• Engine installed.
• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
• Change the engine oil if it is dirty.
• When using sealant, observe the current descriptions, refer to the electronic parts catalog ETKA.
- Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.
- Remove the engine cover and air filter.
Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.
- Open cap of coolant expansion tank.
- Remove noise insulation.
- Remove the right noise insulation - fasteners - 1 to 3 -.
- Drain engine coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Pry off the caps on the wiper arms with a screwdriver and remove the nuts.
- Pull off and remove wiper arms from wiper axles.
- Unclip the spray nozzles - arrow -.
- Push the spray nozzles, with lines still attached, back through the opening and into the plenum chamber.
- Remove rubber seal - 1 - for plenum chamber cover.
- Remove the plenum chamber cover - 2 -.
- Free up the rear engine wiring harness at the partition for plenum chamber.
- Remove electrical connector - arrow - for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.
- Remove partition for plenum chamber - arrows -.
- Disconnect the coolant line to coolant expansion tank - arrow -.
- Disconnect coolant hose - 1 -.
- Disconnect coolant hose - 2 -.
- Remove ground (GND) wire bolt - 1 -.
- Separate electrical connector - 2 -.
- Disconnect coolant hoses - arrows -.
- Remove the intake manifold.
- Remove catalytic converter with front exhaust pipe. Refer to => [ Front Exhaust Pipe with Catalytic Converters and Front Muffler ] Service and Repair.
- Remove right drive axle.
- Remove the right drive axle heat shield - arrows -.
- Disconnect air guide pipe - arrow - from charge air cooler.
- Unfasten air duct from turbocharger - arrows -.
- Disconnect the connectors - 1 and 2 - and free up the cable.
- Remove bolts - arrows - and remove air guide pipe.
• The illustration depicts the engine removed from behind.
- Unfasten turbocharger oil supply line at cylinder block - 1 -.
- Remove turbocharger oil supply line - 2 -.
- Unfasten turbocharger coolant supply line at cylinder block - 1 -.
- Remove coolant supply line to turbocharger - 2 -.
- Remove the coolant supply line for turbocharger - 3 - at the cylinder block.
- Disconnect oil return line - arrows - on turbocharger.
- Remove bolts - 1 - and - 2 - and remove support for turbocharger.
- Remove toothed belt. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, Without Divided Toothed Belt Guard or => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, With Divided Toothed Belt Guard.
- Loosen the bolt for camshaft sprocket using the (3036).
- Pull off the camshaft sprocket using the (T40001) and claws (T40001/6) and (T40001/7).
- Remove the rear toothed belt guard - arrows - from cylinder head.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Loosen the cylinder head bolts using a (T10070) , paying attention to the sequence of the cylinder head bolts.
• Verify that all hose and line connections between engine, transmission and body have been disconnected.
- Remove cylinder head.
Cylinder Head, Installing
• Tightening specifications and tightening sequence, refer to => [ Cylinder Head Overview ] Cylinder Head Overview
• For the correct tightening specifications, refer to => [ Exhaust System Overview ] Exhaust System Overview
• Replace the cylinder head bolts.
• Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings.
• Secure all hose connections using hose clamps of series-production status, refer to the electronic parts catalog ETKA
• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Hot bolt paste, refer to the electronic parts catalog ETKA
Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).
• Turning over the engine is performed at the center bolt of the crankshaft.
- Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts - arrows - now face toward each other vertically.
- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
- Set cylinder head gasket in place.
• Pay attention to alignment pins - arrows - in cylinder block.
• Observe cylinder head seal location, identification: Replacement part number must be visible from intake side.
- Set cylinder head in place.
- Insert cylinder head bolts and tighten by hand.
- Cylinder head tightening sequence => [ (Item 13) Bolt ] Turbocharger Overview:
• There is no requirement to tighten the cylinder head bolts after repairs.
- Install cylinder head cover. Refer to => [ Cylinder Head ] Cylinder Head.
- Install wiper arm.
- Install toothed belt. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, Without Divided Toothed Belt Guard or => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, With Divided Toothed Belt Guard.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Electrical connections and routing.
- Install the intake manifold.
- Install air guide pipes and connector. Refer to => [ Hose Connections with Connector Couplings ] Service and Repair.
- Connect the battery.
- Install fuel system.
- Check oil level.
- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant may not be used again.
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.