Removal and Installion
CYLINDER HEAD, REMOVING AND INSTALLING:
NOTES:
^ The cylinder head can be removed or installed with engine installed.
^ When installing an exchange cylinder head, the contact surfaces between the hydraulic lifter and cam must be oiled after installation.
^ The plastic protectors fitted to protect the open valves must only be removed just before installing the cylinder head.
^ When replacing the cylinder head; also replace the complete coolant
1 - Cap
2 - Oil filler tube
3 - Cover cap
4 - 10 Nm (7 ft lb)
5 - to intake hose
^ Breather hose secured to oil filler tube (item -2-) with retainer
^ Ensure sufficient clearance to throttle body
6 - Positive Crankcase Ventilation valve
7 - Sealing ring
^ Replace if damaged
8 - Cylinder head cover
^ Replace complete if damaged or leaking
^ With oil deflector
9 - Dished washer
10 - Upper sealing washer
^ Replace if damaged
11 - Valve cover gasket
^ No longer available as a spare part, replace valve cover assembly if leaking
12 - Cylinder head bolt
^ Loosening and tightening sequence
13 - 15 Nm (11 ft lb)
14 - Distributor
15 - 0-ring
^ Replace it damaged
16 - Cylinder head
^ Check for distortion
^ Removing and installing
^ Valve gear, servicing
^ After replacing, completely replace the coolant
17 - Cylinder head gasket
^ Note installation position
^ Replace
^ After replacing, completely replace the coolant
18 - 2ONm (15 ft lb)
19 - Bracket
20 - 20 Nm (15 ft lb)
21 - Tensioner
^ from 10.91
^ Removing, installing and tensioning toothed belt Service and Repair
22 - Washer
^ With locking tab
23 - 15 Nm (11 ft lb)
24 - Front toothed belt guard. upper section
25 - Camshaft sprocket mounting bolt
^ Observe steel type marking on bolt head:
8.8 = 85 Nm (63 ft lb)
10.9 = 100 Nm (74 ft lb)
^ Counter-hold with 3036 to loosen and tighten
26 - Toothed belt
^ Check for wear
^ Do not kink
^ Removing and installing Service and Repair
27 - Camshaft sprocket
^ Note position when installing the toothed belt Service and Repair
28 - Toothed belt guard, rear
^ To remove cylinder head loosen mount
29 - Woodruff key
^ Check for tight fit
30 - to junction on Coolant expansion tank Service and Repair
31 - Intake manifold
CYLINDER HEAD, DISTORTION CHECKING:
Fig. 1 Cylinder head, distortion checking:
^ Max. permissible distortion: 0.1 mm
CYLINDER HEAD, REMOVING AND INSTALLING:
Special Tools, Testers And Auxiliary Items:
^ VAG 1332 Torque wrench 40 to 200 Nm (30 to 148 ft lb)
^ 3070 Guide pins
^ Emery paper
Test Conditions:
^ Engine cold
^ Pistons NOT at TDC
NOTES:
^ Only remove the new cylinder head gasket from its packaging lust before installing.
^ Handle the new gasket with extreme care. Damage to the silicone coating in the beaded area will lead to leaks.
Removing:
- Follow sequence when loosening/tightening cylinder head bolts.
Installing:
- Carefully remove any gasket remnants, ensure that no long scores or scratches are formed (do not use a coarser grade of abrasive paper than 100 grit).
- Carefully remove any remaining metal or abrasive particles.
- Center the cylinder head by installing the 3070 screw guide pins into cylinder head bolts -9- and -10-.
- Install cylinder head gasket.
^ if installed correctly, part number lettering must be readable.
- Install cylinder head, screw in 10 remaining cylinder head bolts and tighten by hand.
- Remove guide pins with removal tool from 3070 and install cylinder head bolts.
- Tighten cylinder head in four stages in sequence shown as follows:
- 1. Tighten initially with torque wrench:
Stage I = 40 Nm (30 ft lb)
Stage II = 60 Nm (44 ft lb)
- 2. Turn further with normal spanner:
Stage III = 1/4 turn (90°)
Stage V = 1/4 turn (90°)
NOTES:
^ Loosening cylinder head: Reverse sequence of tightening.
^ Re-torquing cylinder head after repairs is not necessary.