Removal and Installation
Cylinder head, removing and installing
Note: Depending on the version of the engine, the cylinder head cover is made out of steel sheet or light metal.
When installing an exchange cylinder head fitted with camshaft; the contact surfaces between the hydraulic lifter and the cam must be oiled BEFORE installing the new cylinder head cover.
DO NOT remove the plastic packing pieces used to protect the open valves until immediately before installing the cylinder head.
If the cylinder head is replaced; also replace all engine coolant.
1. Cap
2. Gasket
Replace if damaged
3. Vent housing
Only cylinder head covers made of steel sheet
Turn to the right to remove
4. Gasket
Only cylinder head covers made of steel sheet
Always replace
5. Bracket
Only cylinder head covers made of steel sheet
6. 10 Nm (7 ft. lbs.)
7. To crankcase breather valve
8. 10 Nm (7 ft. lbs.)
9. Bracket
10. Oil seal
Always replace
11. Sealing plug 15 Nm (11 ft lbs)
Always replace
12. Cylinder head bolt
Always replace
Observe sequence when loosening or tightening.
13. Connection
14. Oil Seal
Replace if damaged
15. 20 Nm (15 ft lbs)
16. Lifting eye
17. Cylinder head gasket
Always replace
After replacing renew the complete coolant
Note installation position
18. 15 Nm (11 ft lbs)
19. Camshaft drive belt guard, rear
20. Camshaft drive belt
Mark engine direction of rotation before removing.
Check for wear
Do Not kink.
21. Cylinder head
Distortion checking -> Fig. 1
If replaced also replace all engine coolant
22. Oil deflector
23. Cylinder head cover gasket
Replace if damaged
Before installing gasket, coat transition between camshaft bearing cap/cylinder head with D 454300 A2
24. Cylinder head cover
Light metal made
25. Cylinder head cover
Steel sheet made
26. Reinforcing strip
Only cylinder head covers made of steel-sheet.
27. Camshaft drive belt guard
Only cylinder head covers made of steel-sheet
Fig. 1 Cylinder head distortion, checking
Special tools, testers, measuring instruments and auxiliary items required
Feeler gauges
Straight edge
Maximum permissible distortion: 0.1 mm
Cylinder head, removing and installing
Special tools and equipment
3450/2A Head gasket aligner
3450/3, 3450/2A complement
T10029 Spark plug connector tool
VAG 13O6 Drip tray
VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb)
VAG 1332 Torque wrench 40 to 2OO Nm (30 to 148 ft lb)
VAG 1921 Spring clip pliers or VAS 5024 Assembly tool for spring- type clip
Requirements
Engine must not be hotter than warm to the touch.
Pistons must NOT be positioned at TDC.
Work sequence
Observe safety precautions
Observe rules of cleanliness
CAUTION! Obtain radio anti-theft code from customer BEFORE disconnecting battery Ground strap!
With ignition switched OFF, disconnect battery Ground strap
Remove engine cover
Note: All cable ties which are opened or cut open to remove the engine, must be replaced in the same position when reinstalling the engine.
Drain coolant.
Remove intake manifold upper section.
Note: Seal off open portions of lower intake manifold against dirt etc. with clean shop rags.
Remove hoses from cylinder head using pliers VAG 1921 or VAS 5024.
WARNING! Fuel system is under pressure! BEFORE opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
Pull off supply line/hose -1- (with white marking) and return line/hose -2- (with blue marking) at fuel rail connection, and collect fuel that leaks out with a cloth.
Seal fuel lines so that system is not contaminated by dirt etc.
Remove air cleaner with intake hose.
Remove vacuum and pressure lines/hoses for secondary air pump.
Unbolt and remove secondary air pump motor and bracket.
Remove front exhaust pipe with catalyst from exhaust manifold.
Remove camshaft drive belt guard upper section.
Remove ribbed belt.
Remove ribbed belt tensioning element with bracket.
Set camshaft sprocket to TDC No.1 cylinder by turning crankshaft.
Mark on camshaft sprocket must align with -arrows- on cylinder head.
Release tensioning roller and take toothed belt off camshaft sprocket.
Turn camshaft back slightly.
Remove cylinder head cover.
Unscrew upper bolt from rear belt guard.
Cylinder Head Bolts Removing Sequence:
Loosen cylinder head bolts in prescribed sequence and then remove completely.
Carefully lift off cylinder head.
Installing
Note: Always replace cylinder head bolts.
There must NOT be any oil or coolant in the bolt pockets in the cylinder head or there is the danger of creating a hydro-lock while torquing which could lead to structural damage.
Only remove the new cylinder head gasket from its packaging immediately before installing.
Handle the new gasket with extreme care. Damage will lead to leaks.
Place a clean cloth over cylinders so no dirt or abrasive particles can get between cylinder wall and piston.
Take whatever precautions are necessary to prevent dirt and abrasive particles from getting into coolant system. Also prevent dirt and emery cloth particles from getting into coolant.
Carefully clean cylinder head and cylinder block sealing surfaces, ensuring that no scores or scratches are formed. (When using abrasive paper, grade must NOT be LESS than 100).
Carefully remove all traces of metal particles, emery remains and cloth.
If crankshaft has been turned, set cylinder No.1 piston to top dead center and then turn crankshaft back slightly.
To centralize, screw guide pins from 3450/2A into front outer holes for cylinder head bolt (as shown).
Note: The tolerance at the upper end of the centralizing holes has been reduced. Therefore, before fitting the cylinder head check whether the guide pins can be removed upward. If necessary, grind down the knurling on the guide pins.
Cylinder Head Bolt Tightening Sequence:
Install new cylinder head gasket.
Lettering (part number) must be readable.
Install cylinder head, screw in 8 remaining head bolts and tighten by hand.
Unscrew 3450/2A guide pins through bolt holes using 3450/3 pin driver by turning it counter-clockwise until pins are free.
Install remaining cylinder head bolts and tighten hand-tight.
Tighten cylinder head in tightening sequence as follows:
Cylinder Head Bolt Tightening Sequence:
Pretighten all bolts to 40 Nm (30 ft lbs).
Tighten all bolts 1/4 turn (90°) further using a rigid wrench.
Tighten all bolts a 1/4 turn (90°) further.
Note: When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
The rest of the assembly is basically a reverse of the disassembly sequence.
Install camshaft drive belt and adjust timing.
Install ribbed belt tensioner. Torque: 25 Nm (18 ft lbs).
Install ribbed belt.
Fill with new coolant.
Check Diagnostic Trouble Code memory.
Match Engine Control Module (ECM) to Throttle Control Module.
Check Readiness code.
Reset Readiness code after DTCs are corrected, Engine Control Module (ECM) is subject to low voltage with ignition on, or ECM is replaced.