Left Cylinder Head
Left Cylinder Head
Special tools, testers and auxiliary items required
• Drip tray (V.A.G 1306)
• Torque wrench (5 to 50 Nm) (V.A.G 1331)
• Torque wrench (40 to 200 Nm) (V.A.G 1332)
• Spring-type clip pliers (VAS 5024A)
• Cable tie
Requirement
• The engine must be no more than warm to touch.
Removing
- Remove engine --> [ Engine, Removing ] Engine Removing.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.
- All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
- Remove front exhaust pipe from exhaust manifold --> [ Exhaust Manifolds with Primary Catalytic Converters and Attachments,
Assembly Overview ] Exhaust Manifolds with Primary Catalytic Converters and Attachments, Assembly Overview.
- Remove oil dipstick guide tube - arrow - from cylinder head.
- Disconnect connectors - 2 - and - 3 -.
- Remove toothed belt --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning.
- Remove camshaft gear --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning, Toothed belt, removing, installing and tensioning.
- Remove bolts - 1 - and - 2 - and remove rear toothed belt cover.
- Disconnect vacuum hose - 1 - from combination valve.
- Remove bolts - 2 -.
- Disconnect connector - 3 -.
- Remove bolts - 4 - and remove oil pipe.
- Remove bolts - 5 - and remove combination valve.
- Remove bolts - arrows - from coolant pipe.
- Disconnect knock sensor connectors.
- Disconnect connectors from all fuel injectors.
- Disconnect connector - 1 -.
- Disconnect hose - 2 -.
- Remove bolts - 8 -.
- Disconnect connector - 9 -.
- Remove coolant pipe.
- Remove intake manifold --> [ Intake Manifold, Assembly Overview ] Intake Manifold, Assembly Overview.
- Remove cylinder head cover --> [ Left Cylinder Head Cover ] Left Cylinder Head Cover.
- Loosen and remove cylinder head bolts in specified sequence starting from outside working toward inside.
- Carefully lift cylinder head off.
- Stuff clean cloths into cylinder so that no dirt or abrasive powder can get between cylinder wall and piston.
- Also prevent dirt and emery cloth particles from getting into coolant.
- Carefully clean cylinder head and cylinder block sealing surfaces. This ensures that no scoring or scratches are formed (when using abrasive paper the grade must not be less than 100).
Installing
- Carefully remove metal particles, emery remains and cloths.
• Only remove the new cylinder head gasket from its packing immediately before installing.
• Handle new gasket with extreme care. Damaging will lead to leaks.
- Install new cylinder head gasket. Install new cylinder head gasket. Inscription (Part No.) must be legible.
- Ensure that alignment bushings - arrows - are inserted into cylinder block and that cylinder head gasket is seated.
- Install cylinder head, insert new cylinder head bolts and hand tighten.
- Tighten cylinder head bolts in tightening sequence as follows from inside to outside.
- Pre-tighten all bolts to 35 Nm.
- Then tighten all bolts to 60 Nm.
- Tighten all bolts (1/4 turn) (90°) further using a rigid wrench.
- Afterwards, tighten all bolts again 1/4 turn (90°) further
Adjusting valve timing --> [ Toothed Belt, Removing, Installing and Tensioning ] Toothed Belt, Removing, Installing and Tensioning.
- Install cylinder head cover --> [ Left Cylinder Head Cover ] Left Cylinder Head Cover.
- Install intake manifold --> [ Intake Manifold, Assembly Overview ] Intake Manifold, Assembly Overview.
The rest of assembly is in reverse order of disassembling.
• There is no requirement to re-tighten the cylinder head bolts after repairs.