Removal and Installion
Special tools, equipment, test and inspection devices; required accessories
- 2024A Engine sling
- 3268 Camshaft ruler
- VAG 1202A Shop crane
- VAG 1306 Drip pan for VAG 1202A
- VAG 1331 Torque wrench (5-50 Nm) or equivalent
- VAG 1332 Torque wrench (40-200 Nm) or equivalent
- Spring band clamp pliers VAG 1921
Prerequisites
- The engine must not be warmer than hand temperature.
Removing
Note: The ground strap must be disconnected for this procedure. Check to see if a coded radio is installed. If that is the case, you must first obtain the anti-theft code.
- With ignition off, disconnect battery ground strap.
- Remove upper half of intake manifold. Refer to "Engine : Intake Manifold : Service and Repair" Service and Repair
- Loosen or disconnect following components:
- High voltage line from ignition coil
- Ground strap at ignition coil
- Position crankshaft at oscillation damper retaining screw in engine cranking direction to marker TDC cyl. 1 -arrow.
- Drain coolant.
- Remove cylinder head cover.
- Disconnect injector valve connector and disconnect vacuum hose from fuel pressure regulator.
- Loosen spring band clamps and disconnect coolant hoses from thermostat housing.
- Remove thermostat housing.
- Remove electrical coolant return pump (V51) from its retainer. Coolant hoses may remain connected.
- Disconnect three-wire Hall Camshaft Position (CMP) sensor -G40- -arrow-, do not remove sensor.
- Remove ignition coil -Nl52-.
- Remove camshaft roller chain chain tensioner.
- Unscrew camshaft cover.
- Loosen camshaft sprockets, however, while doing this, hold camshafts in place with fork wrench SW24.
Note: Use only fork wrench SW 24 -arrow- to press against camshaft. Camshaft ruler 3268 cannot be installed when tightening or loosening the sprockets.
- Remove camshaft sprockets.
- Remove camshaft roller chain track.
- Unscrew exhaust pipe front from exhaust manifold.
- Loosen and unscrew cylinder head screws in order indicated.
- Install suspension device 2024 A as follows and carefully lift cylinder head with shop crane.
- Flywheel side: rail end in position 1
- Oscillation damper side: rail end in position 8
WARNING: Use securing clips at hooks and rail retaining pins.
Notes:
- The bracket markers identified with 1 through 4 point toward the pulley.
- The bores in the perforated rails are counted starting from the hook.
Installing
- Plug cylinder with clean rags, so that dirt or shavings from sanding cannot enter in between cylinder face and piston.
- Also avoid letting dirt and shavings from sanding contaminate coolant.
- Next, carefully clean cylinder head and cylinder block sealing surfaces. Make sure not to create long grooves or scratches (if you are using abrasive paper, its coarseness must be over 100)
- Carefully remove any grinding and polishing residue as well as all cleaning rags.
If piston cylinder 1 is not in TDC position:
- Position crankshaft at oscillation damper retaining screw in engine cranking direction to marker TDC cyl. 1 -arrow.
Notes:
- Do not take the new cylinder head gasket out of its packaging until immediately before installation.
- Use extreme care when handling the new gasket. Damage results in leaks.
- Position new cylinder head gasket. You must be able to read writing (part number) on it.
- Make sure that fitting sleeves have been seated in cylinder head bolt bores 12 and 20 and that cylinder head gasket is in place.
- Position camshafts in cylinder head to cylinder 1 TDC.
- Fasten camshafts with camshaft ruler 3268.
- Next, prepare cylinder head gasket for installation.
- Put cylinder head in place, and manually start cylinder head screws.
- Tighten cylinder head screws as follows in order shown.
- Next, tighten all screws to 50 Nm.
- Next, turn all screws 1/4 turn (90°) with a rigid wrench.
- Finally, turn all screws by another 1/4 turn (90°).
The remaining assembly occurs in reverse order of removal.
Note: Make sure that the oil duct seal O-ring is placed into the cover.
How to adjust the timing, Refer to Timing Components.
How to refill new coolant, Refer to Cooling System.
Note: Retightening of the cylinder head screws is not necessary after repairs.