Cylinder Head

Cylinder Head, Removing

Special tools, testers and auxiliary items required

• Drip tray for workshop crane (VAS 6208)

• Retainer (3036)

• Puller (T40001)

• Ignition Coil Puller (T40039)

• Hose clamp pliers (V.A.G 1921)

• Polydrive bit and drive socket (T10070)

• Toothed Belt Tensioner (T10020)

• Locking Tool (T40098)

Removing

• Engine installed.

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

• Perform oil change if engine oil is contaminated.

• If using sealant, note current specifications.

- Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.

- Remove engine cover - arrows -.





CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

- Open cap of coolant expansion tank.

- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.





- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.





- Drain engine coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures

- Remove toothed belt. Refer to => [ Toothed Belt ] Service and Repair.

- Loosen bolt for camshaft sprocket using Retainer (3036).





- Remove camshaft sprocket using two-arm puller ( T40001) and claw (T40001/6) and claw (T40001/7).





- Remove rear toothed belt housing - arrows - from cylinder head.





- Unfasten Ground (GND) cable - 1 -.





- Disconnect vacuum line to brake booster at bulkhead - 2 -.

- Disconnect EVAP hose - 3 -.

- Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -.





- Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant expansion tank.

- Separate electrical connector from Charge Air Pressure Sensor (G31) - 1 -.





- Remove left charge air hose - 2 -.

- Remove air duct hose - 1 - to turbocharger at bottom right.





- Remove air duct hose - 2 - to charge air cooler at lock carrier.

- Disconnect connector - 1 and 2 - and free up cable.





- Remove oil supply line for turbocharger at cylinder block - 1 -.






- Remove bolt - 2 - of support for turbocharger.

- Remove oil supply line for turbocharger - arrows -.





- Disconnect oil return line - arrows - from turbocharger.





- Loosen bolt - 1 - of support for turbocharger by 2 turns.





- Remove intake manifold.

- Remove catalytic converter. Refer to => [ Catalytic Converter ] Service and Repair

- Remove cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair

- Loosen cylinder head bolts, paying attention to sequence of cylinder head bolts.





• Verify that all hose and line connections between engine, transmission and body have been disconnected.

- Remove cylinder head.

Installing

• Replace cylinder head bolts.

• Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings.

• Secure all hose connections using hose clamps of series-production status.

• 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

CAUTION!
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. Recesses - arrows - now point to 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 centering pins in cylinder block - arrows -.





• 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.

- Tighten cylinder head in sequence indicated, in two stages as follows:





- Tighten with torque wrench:

• 1. Step: 40 Nm

- Tighten using a solid wrench:

• 2. Step: 180° (1/2 turn) further (2 x 90° further is permissible)

• There is no requirement to retighten the cylinder head bolts after repairs.

- Install cylinder head cover. Refer to => [ Cylinder Head, Removing ] Cylinder Head.

- Install toothed belt. Refer to => [ Toothed Belt ] Service and Repair.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Electrical connections and routing.

- Install intake manifold.

- Connect battery.

- 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 must not be re-used.

- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support

- Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.





- Install front bumper cover.

- Check headlight adjustment.

CAUTION!
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.

Tightening Specifications