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Home >> Volkswagen >> 2005 >> New Beetle (1C1) L4-1.9L DSL Turbo (BEW) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Replacement >> Cylinder Head, Removing and Installing

Cylinder Head, Removing and Installing



Cylinder head, removing and installing

CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:

^ Route all types of lines (e.g. for fuel, hydraulic system, coolant, brake fluid, vacuum) as well as the electrical wiring so that the original positions are restored.
^ Ensure that there is sufficient clearance to all moving or hot components.

Note:
^ When installing an exchange cylinder head with an installed camshaft, the contact surfaces between the hydraulic lifters and the cam must be oiled before installing the cylinder head cover.
^ The plastic packing pieces for protecting the open valves must not be removed until immediately before installing the cylinder head.
^ If the cylinder head is replaced, all the coolant in the system must also be replaced.






Special tools, testers and auxiliary items required
^ Drip tray V.A.G1306
^ Torque wrench V.A.G1331
^ Torque wrench V.A.G1332
^ Vacuum pump V.A.G1390
^ Bleeder bottle V.A.G 1390/1
^ Bracket T10014

Special tools, testers and auxiliary items required





^ Supplementary hook 10-222 A/2

Removing

CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
^ Route all types of lines (e.g. for fuel, hydraulic system, coolant, brake fluid, vacuum) as well as the electrical wiring so that the original positions are restored.
^ Ensure that there is sufficient clearance to all moving or hot components.

- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Remove plenum chamber cover (outer) and plenum chamber sealing part.
- Remove air cleaner housing with intake hose.
- Drain coolant.
- Remove front exhaust pipe.

CAUTION:
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure.
^ Wear eye and hand protection when performing any type of repair work on the fuel system!

- Extract fuel from tandem pump.
- Pull off/separate connections for glow plugs, fuel temperature sender, pump/injector units (central connector) and coolant temperature sensor.





- Pull fuel hoses and coolant hose off pipes on cylinder head - arrows -.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Pull off coolant hose - 1 - and connectors - 2 - from pipe union.
- Pull hose off vacuum reservoir.
- Separate quick release coupling on right side at heat exchanger (from exhaust gas heat exchanger).





- Separate hose connections - 1 - on non-return valve and - 3 - to vacuum reservoir. Pull union - 2 - off brake servo.
- Pull union - 2 - off brake servo.
- Separate vacuum hoses for bypass flap (EGR radiator) vacuum units, variable intake manifold and turbocharger at unions.





- Pull connector - 1 - off.
- Remove connecting hose - 7-.
- Pull vacuum hose - 5 - off rear charge air pipe - 6-.
- Separate connecting hose at rear charge air pipe - 6 - and remove it.
- Disconnect oil return line - 2 - from union on cylinder block.
- Remove bolts - 3 - and - 4 - and take bracket off.





- Disconnect oil supply line at oil filter bracket - arrow - and additionally at coolant pipe.





- Disconnect oil supply line at exhaust gas turbocharger and exhaust manifold - arrows - and move aside.





- Remove toothed belt.

Note:
^ Both lifting eyes for the support are located on the cylinder head, so an additional bracket for supporting the engine must be secured on the cylinder block.
^ Hook spindle - B - onto cylinder head.

- Turn crankshaft back slightly.
- Remove camshaft sprocket hub.
- Remove toothed belt tensioning roller.
- Remove coolant pump and idler roller.
- Remove Camshaft Position (CMP) sensor.
- Remove rear toothed belt guard.





- Screw bracket T10014 into forward threaded hole of removed engine bracket in area of water pump in cylinder block, as shown.
- Lift engine slightly using second spindle - A - and supplementary hook 10-222A/2 until spindle - B - is relieved.
- Unhook spindle - B - from lifting eye - 1 - and slide to side.
- Remove cylinder head cover Cylinder head cover, removing and installing.





- Loosen and remove cylinder head bolts in sequence.
- Lift cylinder head out with help of an assistant.

Installing

Note:
^ Always replace cylinder head bolts.
^ When repairing, carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long grooves or scratches are created. When using abrasive paper do not use a grade less than 100.
^ Carefully remove emery and abrasive remains.
^ Blow forcibly into the threaded holes for the cylinder head bolts. Place a cloth onto the respective hole for protection against oil splashing.
^ Only unpack new cylinder head sealant immediately prior to installation.
^ Handle the new gasket with extreme care. Damage to the silicone film and in the depression area will result in leaks.
^ Charge pressure hoses and pipe connections must be free of oil and grease before reinstalling.

- Turn crankshaft to TDC marking.
- Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below TDC.





- Observe cylinder head gasket identification.
^ Part No. = arrow 1
^ Control code = Arrow 2 (not significant!)
^ Hole(s) = Arrow 3

Note:
^ If the cylinder head gasket or the cylinder head are replaced, use a new cylinder head gasket with same number of holes as the old gasket.
^ If components of the crankshaft system have been replaced the new cylinder head gasket must be determined by measuring the piston projection in TDC.





- Install cylinder head gasket.
^ Observe centering sleeves - arrows - in cylinder block.
^ Observe head gasket installation position, lettering or Part No. must face cylinder head.
- Fit cylinder head and cylinder head bolts, and tighten by hand.





- Tighten cylinder head in four stages in sequence shown as follows:
^ Pre-tighten all bolts to 40 Nm.
^ Pre-tighten all bolts to 60 Nm.
^ Then tighten all bolts 1/4 turn (90°) using a rigid wrench.
^ Finally tighten all bolts again a further 1/4 turn (90°) using a rigid wrench.

Note:
^ Retightening of the cylinder head bolts after repairs is not required.





- After tightening cylinder head, turn camshaft hub so that cam lobes for cylinder No. 1 - arrows - point evenly upward.

The remaining installation is in reverse order. Note the following points.

CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
^ Route all types of lines (e.g. for fuel, hydraulic system, coolant, brake fluid, vacuum) as well as the electrical wiring so that the original positions are restored.
^ Ensure that there is sufficient clearance to all moving or hot components.

- Observe tightening sequence of securing bolts when installing oil return pipe.
- Before installing toothed belt, turn crankshaft in direction of engine rotation to TDC and lock in position using crankshaft stop T10050.
- Read Diagnostic Trouble Code (DTC) memories of all control modules, repair faults if necessary and then erase DTC memory.
- Test drive vehicle and read DTC memory of all control modules again.

Note:
^ Observe applicable safety precautions during the road test.
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