Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip Tray (V.A.G 1306)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Spring Type Clip Pliers (VAS 5024A)
• Polydrive Bit and Drive Socket (T10070)
• Ignition Coil Puller (T40039)
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 (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
Removing
• The engine must be no more than warm to touch.
• All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.
• Perform an oil change if the engine oil is contaminated.
- Check if a coded radio is installed. If so, obtain the anti-theft code, if necessary.
- With the ignition turned off, disconnect the battery Ground (GND) cable.
GTI and Eos
- Remove the plenum chamber bulkhead.
Continuation for All
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
- Remove the front part of the right wheel housing liner.
- Remove the exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the charge air hose - arrow - from the charge air cooler.
- Remove the charge air pipe bolts - arrows - and disconnect the charge air pipe.
- Disconnect all electrical wires from the turbocharger and set aside.
- Remove the oil supply line and coolant supply line bolts - arrows - from the turbocharger.
- Remove the oil return line bolts - arrows - from the turbocharger.
- Remove the bolts - 1 and 2 - and remove the turbocharger support.
- Remove the battery, the battery tray bolts - arrows - and tray.
- Disconnect coolant hoses - 1 and 2 -.
- Disconnect all electrical wires required from the cylinder head and set aside.
- Remove the wire bracket bolts - arrow - and move the wiring harness aside.
- Remove the coolant connection bolts - arrows -.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the (T10060A) from the belt tensioner.
- Remove the toothed belt, refer to one of the following:
=> [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, With Divided Toothed Belt Guard.
=> [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, Without Divided Toothed Belt Guard.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Follow the sequence for loosening the cylinder head bolts.
• Verify that all hose and line connections to the engine, transmission and body have been disconnected.
- Remove the cylinder head.
Installing
• 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.
• Replace the cylinder head bolts.
- Insert clean cloths into the cylinders so that no dirt or abrasive powder can get between the cylinder wall and the piston.
- Do not allow dirt or abrasive powder to get into coolant either.
- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
- Carefully remove any metal particles, emery remains and the cloths.
- If the crankshaft was turned in the meanwhile: bring the piston for cylinder 1 to Top Dead Center (TDC) and then turn the crankshaft back just a little.
- Install the new cylinder head gasket. the text (replacement part number) must be visible.
- Note the alignment pins - arrows - in the cylinder block.
- Install the cylinder head.
- Install the cylinder head bolts and tighten them hand tight.
- Tighten the cylinder head bolts in the sequence shown as follows:
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Install the toothed belt, refer to one of the following:
=> [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, With Divided Toothed Belt Guard.
=> [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, Without Divided Toothed Belt Guard.
The rest of the installation is basically a reverse of the removal sequence.
Fill the cooling system. Refer to => [ Draining and Filling ] Procedures.