Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Hose Clip Pliers (V.A.G 1921)
• Polydrive Bit and Drive Socket (T10070)
Removing
• Engine installed.
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.
- Remove the engine cover - arrows -.
- Remove fan shroud. Refer to => [ Fan Shroud ] Service and Repair.
- Remove the turbocharger. Refer to => [ Turbocharger ] Turbocharger.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the protective boot - 2 - and disconnect the fuel hose by pressing the release ring.
- Remove the hose - 1 -.
- Release the EVAP canister - B arrow -, remove it upward - A arrow - and lay it aside.
- Remove the bolt and nut - arrows - and then push the front right coolant pipe to the side with the coolant hoses still connected.
- Remove the double bolt - arrow - for the oil dipstick guide tube.
- Disconnect the connector - 3 -.
- Remove bolt - arrow -.
- Remove the hose - 2 -.
- Loosen the hose clamp - 1 - and then remove the turbocharger recirculating valve (N249) with the hose still connected - 4 - from the air guide pipe and lay it to the side.
- Disconnect the connector - arrow - on the charge air pressure sensor (G31).
- Remove the bolt - 1 - and nut - 4 -.
- Loosen the hose clamp - 2 - and remove the air guide pipe.
• Ignore - 3 -.
- Disconnect the connector - 1 - on the Intake Air Temperature (IAT) Sensor 2 (G299).
• Ignore - arrow -.
- Disconnect the connector - 1 -.
- Remove bolts - arrows - and remove throttle valve control module (J338).
- Remove the nut - 2 - and screw - 1 - and remove the intake manifold support.
- Disconnect the connectors on the low fuel pressure sensor (G410) - 1 - and on the fuel pressure regulator valve (N276) - 2 -.
- Free up electrical wires.
• Ignore - arrows -.
- Remove the crankcase ventilation hose - 1 - from the oil separator by pressing the release buttons.
- Disconnect the connectors:
2 For the injector valves, remove the connectors from the bracket
3 For evaporative emission (EVAP) canister purge regulator valve 1 (N80)
4 Intake flap motor (V157)
5 Fuel pressure sensor (G247) and camshaft position sensor (G40) , remove the connectors from the bracket
- Disconnect the connector - 1 -.
- Remove the wiring harness - 2 - from the bracket.
• Ignore - 3 -.
- Free up the wiring harness - arrows - and remove the bracket bolt - 1 -.
- Remove ground (GND) wire - 1 -.
- Disconnect the connector - 2 -.
- Remove the coolant hoses and the vacuum hoses - arrows -.
- Toothed belt, removing. Refer to => [ Toothed Belt ] Toothed Belt.
- Remove cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Loosen the cylinder head bolts in the following sequence - 1 through 10 -.
- Remove bolts and remove cylinder head.
Installing
• Tightening specifications, refer to => [ Cylinder Head Cover and Cylinder Head Overview ] Cylinder Head Cover and Cylinder Head Overview, => [ Cylinder Head, Tightening Specifications
and Sequence ] Cylinder Head Cover and Cylinder Head Overview.
The sealing surfaces could be damaged.
• Carefully remove sealant residue from cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging cylinder block.
• No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.
Risk of leaks in cylinder head seal.
• Carefully remove sealant residue 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.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.
• Replace bolts which have been tightened to torque.
• Replace self-locking nuts, sealing rings, seals and O-rings.
• If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the camshaft housing.
• The hose supports, air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.
• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.
- Align the marking on the toothed belt camshaft pulley with the marking on the toothed belt guard - top arrow -.
• The cams - A - on both camshafts are symmetrical to each other.
• The notches - arrows - on both camshafts must align.
- Clean the sealing surfaces; they must be free of oil and grease.
- Make sure the crankshaft is still at "TDC" and then turn it back 45° opposite the engine rotation.
- Set cylinder head gasket in place.
• Installed position: It must be possible to read the part number.
• Note the sleeves in the cylinder block.
- Set cylinder head in place.
- Tighten the cylinder head bolts. Refer to => [ Cylinder Head, Tightening Specifications
and Sequence ] Cylinder Head Cover and Cylinder Head Overview.
• Do not tighten cylinder head bolts after repairs.
- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Rotate the crankshaft back to "TDC".
- Install toothed belt (adjust timing) => [ Installing (Adjusting
valve timing) ] Toothed Belt.
- Install the intake manifold support and throttle valve control module (J338).
- Tighten the oil dipstick guide tube. Refer to => [ Oil Dipstick Guide Tube - Tightening
Specifications ] Oil Pan Overview.
- Install the air guide pipe. Refer to => [ Charge Air Cooler Overview ] Charge Air Cooler Overview.
- Install the right front coolant pipe. Refer to => [ Right Front Coolant Pipe ] Right Front Coolant Pipe.
- Install the turbocharger. Refer to => [ Turbocharger ] Turbocharger.
- Install fan shroud. Refer to => [ Fan Shroud ] Service and Repair.
- Electrical connections and routing.
- Change engine oil.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.