Removal and Installion

Cylinder head, removing and installing





Special tools and equipment
^ 3452 polydrive key
^ VAG1306 drip tray
^ VAG1331 torque wrench (5 to 50 Nm)
^ VAG1332 torque wrench (40 to 200 Nm)
^ VAS5024 assembly tool for spring type clamps

Requirements
^ Engine must not be hotter than lukewarm.
^ Pistons must not be at Top Dead Center (TDC).

Procedure
- First determine whether a coded radio is installed. If so, determine the correct coding.
- Switch ignition off and disconnect Battery Ground (GND) strap.
- Drain engine coolant, Refer to Cooling System.
- Disconnect fuel supply line and return line at connection point at fuel rail. Fuel system is under pressure. Therefore place rags around the connection before disconnecting hoses.
- Seal off lines so that no dirt will get into fuel system.
- Unbolt catalytic converter from turbocharger.
- Disconnect all necessary connections:
^ Cooling system
^ Crankcase breather valve
^ Secondary air system
^ Exhaust turbocharger/regulation
^ Fuel injection and ignition system
- Remove upper portion of toothed belt guard.
- Loosen tensioner and lift toothed belt from camshaft gear.
- Remove cylinder head cover.





- Loosen and unbolt cylinder head bolts in specified sequence using 3452 polydrive key.
- Carefully remove cylinder head.

Installing

Notes:
^ Pocket holes in engine block for cylinder head bolts must be free of oil and coolant.
^ Do not remove new cylinder head gasket from package until immediately before installing.
^ Handle new gasket extremely carefully. Damage will cause leaking.
- Stuff clean cloths into cylinders so that no dirt or abrasive powder can get between cylinder wall and piston.
- Do not allow dirt or abrasive powder to get into coolant either.
- Carefully clean sealing surfaces of cylinder head and cylinder block. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
^ Thoroughly remove all sanding and grinding residue and remove cloths.
^ Set piston of 1. Cylinder in TDC position and slightly turn crankshaft backward.





- Position new cylinder head gasket.
^ Pay close attention to pilot pins in cylinder block (arrows).
^ Pay close attention to cylinder head seal; replacement part number must be legible.
- Install cylinder head.
- Insert new cylinder head bolts and hand-tighten.





- Tighten cylinder head bolts in specified sequence as follows:
- Tighten all bolts to 40 Nm.
- Then tighten all bolts to 60 Nm.
- Then turn all bolts 1/4 rotation (90°) using a rigid wrench.
- Then turn all bolts an additional 1/4 rotation (90°) turn.
The rest of the installation follows the reverse of the removal procedures.
How to install toothed belt and adjust valve timing, Refer to Timing Components.
How to fill up new coolant, Refer to Cooling System.
- Perform work step "Procedure to follow after interruption of voltage supply".
Refer to Powertrain Management.
- Perform road test and check DTC memory:
Refer to Powertrain Management.