Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Removing
Installing
Special tools, testers and auxiliary items required
^ Spring-type clip pliers VAS 5024A
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
Requirement
^ The engine must be no more than warm to touch.
Removing
CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: All cable ties which are opened or cut open when the engine is removed must be replaced in the same position when the engine is installed.
- 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.
- Remove intake manifold cover.
- Remove sound insulation.
- Drain coolant.
- Remove holding plate for intake manifold change-over valve and secondary air injection valve (if equipped) as follows:
- Disconnect connectors for intake manifold change-over valve and Secondary Air Injection (AIR) valve (if equipped).
- Disconnect hoses - 1 to 4 -.
- Remove bolts and nuts - arrows - (10 Nm).
- Remove intake air scoop with connection hose.
- Remove engine coolant expansion tank.
Vehicles with accelerator pedal cable
- Remove vacuum diaphragm for Cruise Control System (only vehicles with CCS).
- Disengage accelerator cable at cable pulley of throttle valve control module and at mounting bracket - arrows - (do not remove positioning clip from mounting bracket).
Continued for all vehicles
- Remove or disconnect following components:
^ connection pipe between Secondary Air Injection (AIR) pump motor and combination valves from combination valves (only vehicles with secondary air injection)
^ Line from Evaporative Emission (EVAP) Canister Purge Regulator Valve
^ Line for crankcase ventilation from cylinder head covers
^ Connector from throttle valve control module
^ Connector from ignition coil power output stages
^ Connector from camshaft adjustment valves and Camshaft Position (CMP) sensors
^ Connector from coolant temperature sensor
^ Vacuum hose from fuel pressure regulator
- Remove fuel rail as follows:
- Disconnect connector from fuel injectors.
- Remove fuel rail from intake manifold and pull out together with fuel injectors.
- Set fuel rail aside (fuel hoses remain connected).
- Unbolt bracket with ignition coils.
- Remove intake manifold with throttle valve control module, disconnect coolant and vacuum lines.
- Remove left combination valve, (only vehicles with secondary air injection system).
- Remove rear coolant line.
- Unbolt front exhaust pipes from exhaust manifolds.
- Perform work steps to remove toothed belt, except:
- Removing vibration damper/belt pulley.
- Removing toothed belt guard/belt pulley.
- Removing bracket for viscous fan clutch.
For cylinder head bank 1 (right)
- Remove air filter.
- Pull out oil dipstick and remove guide tube for oil dipstick.
- Unscrew pressure line for power steering gear from cylinder head cover and rear coolant pipe.
For cylinder head bank 2 (left)
- Remove rear toothed belt guard from cylinder head.
- Remove coolant pipe from front cylinder head.
Continuation for both cylinder heads
- Remove cylinder head cover.
- Loosen socket head bolts in sequence given and then remove completely.
Note: Use polydrive key T10070 for polydrive cylinder head bolts.
- Carefully lift cylinder head off.
Installing
Conditions
^ Crankshaft stands at TDC Cyl. 3 and is secured with crankshaft holder 3242.
Note:
^ There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damaging will lead to 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).
- Clean pocket holes for cylinder head bolts of oil or coolant (blow out carefully using pressurized air).
- Carefully remove metal particles, emery remains and cloths.
- Install new cylinder head gasket. Text (replacement part number) must be visible.
- Before installing cylinder head, position camshafts to TDC Cyl. 3. Arrows on bearing caps - lower arrow - must align with cut-outs - upper arrow - on camshafts.
- Set cylinder head in place. While doing this, note centering pins on cylinder block.
- Insert new cylinder head bolts and tighten by hand.
- Tighten cylinder head bolts in tightening sequence as follows:
- Tighten all bolts to 60 Nm.
- Tighten all bolts 1/4 turn (90°) further using a rigid wrench.
- Afterward, tighten all bolts another 1/4 turn (90°) further.
The rest of the assembly is basically a reverse of the disassembling sequence.
- Fasten exhaust pipe and exhaust manifold.
- Install rear coolant pipe.
- Bolt connection pipe to combination valves, Connection pipe and combination valves, assembly overview.
- Install intake manifold.
- Install fuel rail with fuel injectors.
- Install and tension toothed belt.
- Fill with coolant.
Vehicles with accelerator pedal cable
- Adjust accelerator pedal cable.
- Install vacuum diaphragm for Cruise Control System (only vehicles with CCS).
Continued for all vehicles
- Check Diagnostic Trouble Code (DTC) memory of all control modules, repair all stored malfunctions, and erase DTC memory afterward.
- Road test vehicle and check DTC memory of all control modules again.
Note: Observe safety precautions that apply to road tests.