Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Removing
Installing
Special tools, testers and auxiliary items required
^ Key 3452 (for engines with polydrive cylinder head bolts) *See note
^ Drip tray V.A.G 1306
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Spring-type clip pliers VAS 5024
^ Ignition coil puller T40039 (not illustrated)
^ *The key 3452 was replaced with the socket T10070.
Removing
Requirement
^ The engine must be no more than warm to the touch.
Work sequence
- Check whether a coded radio is installed. If so, obtain radio anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Drain coolant.
- Remove bolts from secondary air injection pump motor and bracket and remove Secondary air system components, assembly overview
CAUTION!
Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Separate supply and return lines on fuel rail union.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove coolant connection union on cylinder head.
- Disconnect interconnecting, coolant, vacuum and intake hoses from cylinder head.
- Disconnect fuel injector connectors.
- Disconnect all necessary electrical wiring on cylinder head and place to side.
- Remove intake air hose from turbocharger union as follows:
Engine code APH
- Pull off pressure control valve hose of crankcase breather - 2 -.
- Disconnect connector of Wastegate bypass regulator valve -N75- - 3 -.
- Disconnect hose - 4 - on Wastegate bypass regulator valve -N75-.
- Separate hose - 5 - from solenoid valve to turbocharger on bulkhead.
Engine codes AWP, AWV, BKF, BNU
- Pull off pressure control valve hose of crankcase breather - 1 -.
- Disconnect connector of Wastegate bypass regulator valve -N75- - 2 -.
- Disconnect hose - 3 - on Wastegate bypass regulator valve -N75-.
- Separate hose between EVAP canister and turbocharger on bulkhead.
Continuation for all engine codes
- Remove securing clamp at turbocharger union and take intake air hose off.
- Remove heat protection mat - 1 - from air duct hose - 2 -, (observe installed position).
- Remove air duct hose - 2 -.
- Loosen two bolts from bracket of upper air duct pipe
- Remove heat protection mat from air duct hose - 3 -, (observe installed position) and loosen clamp - 2 -.
- Remove bolts - 6 - and - 4 - of heat shield at back of cylinder head.
- Loosen bolts - 1 - and - 5 -.
- Take the upper air duct pipe, the hose to the turbocharger and the heat shield off.
- Remove three securing bolts - arrows - at turbocharger-exhaust manifold.
- Remove ribbed belt.
- Remove tensioning element for ribbed belt.
- Remove toothed belt guard upper part.
- Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft pulley must align with arrow on toothed belt guard.
- Mark direction of rotation of toothed belt.
- Remove toothed belt from camshaft sprocket.
- Turn crankshaft back slightly.
- Relieve tension on pressure piston again (remove pin T40011) and remove tensioning bolt T10092.
- Remove ignition coils as follows:
Engine code APH
- Disconnect 4-pin connector - arrow - from ignition coils.
- Remove securing bolts and remove ignition coils with output stages vertically from spark plugs.
Engine codes AWP, AWU, AWV, BKF, BNU:
- Disconnect 4-pin connector - 2 - from ignition coils - 1 -.
- Pull ignition coils with final output stages vertically off of spark plugs with ignition coil puller T40039.
Continuation for all engine codes
- Remove cylinder head cover.
- Loosen socket head bolts in sequence given and then remove.
Note:
^ Use socket T10070 for Polydrive cylinder head bolts.
- Carefully lift cylinder head off.
Installing
Requirement
^ Pistons must not be at TDC, if necessary turn crankshaft back slightly.
Work sequence
Note:
^ There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head.
^ Do not remove new cylinder head gasket from its packing until immediately before installing.
^ Handle new gasket with extreme care. Damage will cause leakage.
- Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
- Also prevent dirt and emery cloth particles from getting into coolant.
- Carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100).
- Carefully remove metal particles, emery residue and cloths.
- Loosen bolts - 1 - and - 2 - at turbocharger bracket approx. 2 turns to avoid stress when installing cylinder head.
- Install new cylinder head gasket. Inscription (Part No.) must be legible.
- Observe centering pins in cylinder block - arrows -.
- Place cylinder head on block.
- Tighten cylinder head in tightening sequence as follows:
- Pretighten all bolts to 40 Nm.
- Then tighten all bolts 1/4 turn (90°) using a rigid wrench.
- Finally tighten all bolts again 1/4 turn (90°) using a rigid wrench.
Note:
^ A further retightening of the cylinder head bolts after these repairs is not required.
- Replace seal between turbocharger-exhaust manifold and install turbocharger and its bracket to cylinder block.
- Install ribbed belt.
- Fill with new coolant.
Further assembly is basically the reverse of the disassembly procedure.
- Interrogate Diagnostic Trouble Code (DTC) memories of all control modules, repair faults if necessary and then erase DTC memory Vehicle diagnosis, Testing and Information system VAS 5051; Guided fault finding; Vehicle system test or Vehicle diagnosis, Testing and Information system VAS 5052; Vehicle self-diagnosis.
- Test drive vehicle and interrogate DTC memory of all control modules again.
Note:
^ Observe applicable safety precautions during road test.