Removal and Installion

Cylinder Head, Removing and Installing

Compression, checking refer to Engine; Compression Check.

Notes:
^ When installing an exchange cylinder head (with camshaft installed), the contact surfaces between the hydraulic lifters and the cam must be oiled before installing the valve cover
^ The plastic packing pieces for protecting the open valves must not be removed until immediately before installing cylinder head.
^ If the cylinder head is replaced, the entire engine coolant must be replaced.
^ Intake manifold, removing and installing.





1. Cap
^ Replace seal if damaged
2. 10Nm (7 ft. lbs.)
3. Cylinder head cover
4. Valve cover gasket
^ Replace if damaged
^ Before installing gasket, coat transition between bearing cap/ cylinder head with D 454 300 A2
5. oil deflector
^ Note installation position:
Above intake camshaft between Nos. 1 and 2 cylinders
6. Cylinder head
^ Check for distortion refer to Fig. 1
^ Reworking sealing surface refer to Valve, Intake/Exhaust, Fig. 1
^ Removing and installing.
^ After replacing, completely replace engine coolant
7. Intake manifold gasket
^ Replace
8. Cylinder head gasket
^ Replace
^ Metal gasket
^ If replaced, completely replace the engine coolant
^ Note installation position: Identification: Part No. must be readable from intake side
9. 25 Nm (18 ft. lbs.)
^ For tensioner
10. Exhaust manifold gasket
^ Replace
^ Note installed position
11. Cylinder head bolt
^ Replace
^ Sequence when loosening and tightening refer to Valve, Intake/Exhaust.
12. Heat shield
13. 25 Nm (18 ft. lbs.)
14. 10 Nm (7 ft. lbs.)





Fig. 1 Cylinder head distortion, checking
^ Max. permissible distortion: 0.1 mm


Cylinder head, removing and installing

Special tools, testers, measuring instruments and auxiliary items required
^ VAG 1306 Drip tray
^ VAG 1921 Spring clip pliers
^ 3070 Guide pin
^ VAG 1332 Torque wrench 40 to 200 Nm (30 to 148 ft. lbs.)

Requirements
^ Engine must not be hotter than just warm to the touch.
^ Pistons must not be positioned at TDC.

CAUTION: Obtain radio security code from customer BEFORE disconnecting the battery Ground cable.

- Ensure ignition is switched OFF
- Disconnect battery Ground cable.
- Drain coolant.

WARNING: Fire hazard. Do NOT have anything in the area that can ignite fuel.

- Separate fuel supply as well as fuel return lines at fuel rail connection. The fuel system is under pressure, therefore place a cloth over the connection before the hoses are pulled off.
- Seal off lines so fuel system is not contaminated by dirt etc.
- Disconnect front exhaust pipe or catalyst from exhaust manifold.
- Remove toothed belt guard - upper section.
- Release tensioner and remove toothed belt from camshaft sprocket.
- Remove valve cover.





- Loosen socket head bolts in exact sequence as given and then remove completely.
- Carefully lift off cylinder head.

Installing

Notes:
^ There must not be any oil or coolant in the cylinder head bolt recesses in the cylinder head.
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damage will lead to leakage.
^ Place a clean cloth in cylinders so that no dirt or abrasive particles can get between cylinder wall and piston.
^ Prevent dirt/abrasive particles from getting into the coolant.
- Carefully clean cylinder head and cylinder block sealing surfaces thereby ensuring that no scoring or scratching can occur.

CAUTION: Do NOT use a coarser grade of abrasive paper than 100. For example, do NOT use 80 grit paper.

- Carefully remove metal particles, abrasive remains and cloths.
- Set cyl. 1 piston to top dead center and then turn crankshaft back slightly.





- Centralize 3070 guide pins into holes for head bolts 8 and 10.
- Install new cylinder head gasket.
^ Lettering (Part No.) must be readable.
- Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
- Remove guide pins using 3070 removal tool by turning tool anti-clockwise until guide pins are free.
- Install remaining cylinder head bolts and tighten hand-tight.





- Tighten cylinder head in tightening sequence as follows:
- Pretighten all bolts to 40 Nm (30 ft. lbs.)
- Then tighten all bolts to 60 Nm (44 ft. lbs.)
- Then tighten all bolts a 1/4 turn (90°) further using a rigid wrench.
- Then tighten all bolts again a 1/4 turn (90°) further.

Notes:
^ Assembly is basically a reverse of the disassembly sequence.
^ Installing toothed belt and adjusting timing.
^ Filling with new coolant.