Cylinder Head, Removing and Installing

Cylinder head, removing and installing





Special tools, testers and auxiliary items required
^ Polydrive wrench 3452
^ Drip tray V.A.G 1306
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Spring-type clip pliers VAS 5024

Removing

Requirements
^ The engine must be no more than warm to touch.
^ The pistons must not be positioned at TDC.
- First, check whether a coded radio is installed. If necessary, obtain anti-theft coding.
- Switch off ignition and all electrical consumers.
- Disconnect battery Ground (GND) strap.
- Drain coolant.
- Observe rules for cleanliness.

CAUTION! Fuel supply line is under pressure! Before loosening the hose connection, place a rag around the connection point. Then release pressure by carefully loosening the hose connection.

- Disconnect fuel supply and fuel return lines at fuel rail.
- Seal lines so that the fuel system is not contaminated by dirt etc.
- Remove catalytic converter from turbocharger.
- Separate all required connections:
^ Cooling system
^ Crankcase ventilation
^ Secondary air injection (AIR) system
^ Turbocharger/regulation
^ Fuel injection and ignition system
- Remove toothed belt from camshaft.
- Remove cylinder head cover.





- Loosen and unscrew cylinder head bolts in specified sequence using polydrive wrench 3452.
- Carefully lift cylinder head off.

Installing

Note:
^ There must be no standing oil or coolant in the cylinder head bolts holes of the cylinder block.
^ Do not remove new cylinder head gasket from package until immediately before installing.
^ Handle the new gasket with extreme care. Damage will result in leaks.

- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
- Do not allow dirt or abrasive powder to get into coolant.
- Carefully clean cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
- Carefully remove metal particles, abrasive residue, and cloths.
- Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.





- Install new cylinder head gasket.
^ Pay close attention to centering pins in cylinder block - arrows -.
^ Pay close attention to cylinder head seal; replacement part number must be legible.
- Set cylinder head in place.
- Insert new cylinder head bolts and tighten by hand.





- Tighten cylinder head in tightening sequence as follows:
- Tighten all bolts to 40 Nm.
- 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

The rest of the assembly is basically a reverse of the disassembling sequence.
- Install toothed belt.
- Add coolant.
- Check DTC memory of all control modules, repair all stored malfunctions, and erase DTC memory afterwards.
- After erasing DTC memory, readiness code must be generated again.
- Perform road test and check DTC memory of all control modules again.

Note: Observe safety precautions that apply to road tests.