Removal and Installion
Cylinder Head Removal And InstallationChecking compression pressures - refer to Compression Check
Note:
^ When installing a reconditioned cylinder head, oil the contact surfaces between valve lifters and cam lobes after installing the head.
^ Remove plastic washers that are supplied to protect the open valves only before actually installing the cylinder head.
^ When replacing the cylinder head, replace the engine coolant
1 - Positive Crankcase Ventilation (PCV) Valve
2 - Grommet
3 - 20 Nm (15 ft lb)
4 - Intake manifold, upper
5 - Gasket
^ Always replace
6 - Cap
^ Replace gasket if damaged
7 - 10 Nm (7 ft lb)
8 - Cylinder head cover
9 - Reinforcement strip
10 - Oil deflector
11 - Cylinder head bolt
^ Always replace
^ Loosening and tightening Sequence - refer to Installing
12 - Gasket
^ Always replace
13 - Cylinder head
^ Installing - refer to Installing
^ Check for distortion - Fig. 1
^ When replacing, always replace engine coolant
14 - Cylinder head gasket
^ Always replace
^ When replacing, always replace engine coolant
15 - Camshaft sprocket
^ Note position when installing drive belt - refer to Toothed Drive Belt, Removing and Installing
16 - Hook eye
17 - Drive belt guard, rear
18 - Toothed drive belt
^ Check for wear
^ Do not kink
^ Removing and installing - refer to Toothed Drive Belt, Removing and Installing
19 - Belt tensioner
20 - 45 Nm (33 ft lb)
21 - Drive belt guard, upper
22 - Drive belt guard
23 - From crankcase breather
Fig. 1 Checking cylinder head for distortion
^ Max. permissible distortion: 0.1 mm (0.004 in.)
Cylinder head, installing
Special tools, testers and auxiliary items
^ Torque wrench VAG 1332 (40-200 Nm)
^ Guide pin 3070
Requirements
^ Engine cold
^ Pistons NOT at Top Dead Center (TDC)
Installing
- To align cylinder head, install guide pins from tool 3070 into holes for cylinder head bolts 8 and 10 (arrows).
- Install cylinder head gasket.
- Install cylinder head (note centering pins in cylinder block).
- Install remaining cylinder head bolts and tighten by hand.
- Remove guide pins from tool 3070, insert cylinder head bolts 8 and 10, and tighten by hand.
- Tighten cylinder head bolts in sequence shown, following same sequence for each of four stages.
Note:
To loosen cylinder head bolts, follow the same sequence in reverse order.
- First tighten with torque wrench.
^ Stage I = 40 Nm (30 ft lb)
^ Stage II = 60 Nm (44 ft lb)
- Then turn further with standard wrench.
^ Stage III = 1/4-turn (90°)
^ Stage IV = additional 1/4-turn (90°)
Note:
After the repairs are complete, no additional re-torquing steps are necessary
Compression pressure, checking
Special tools, testers and auxiliary items
^ Compression tester US 112O
Test conditions
^ Engine oil temperature min. 30°C (86°F)
- Disconnect harness connector for engine speed (RPM) sensor G28.
- Disconnect ignition coil power output stage N157.
- Open throttle all the way (wide open throttle).
- Install compression tester US 1120.
Note:
Using the compression tester - Operating instructions.
- Operate starter until compression tester gauge shows no further pressure increase.
Compression pressure specifications
^ New: 10-13 bar (145-189 psi)
^ Wear limit: 7.5 bar (109 psi)
^ Permissible difference between all cylinders: 3 bar (44 psi)