Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Special tools, testers and auxiliary items required
^ Drip tray V.A.G 1306
^ Torque wrench (5 to 50 Nm) V.A.G 1331
^ Torque wrench (40 to 200 Nm) V.A.G 1332
^ Hand vacuum pump V.A.G 1390
^ Bleed container V.A.G 1390/1
^ Bracket T10014
Special tools, testers and auxiliary items required
^ Support device 10-222A with legs 10-222A/13
Note: All cable ties which are opened or cut through when the cylinder head is removed must be replaced in the same position when the cylinder head is installed.
CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
^ Ensure that there is sufficient clearance to all moving or hot components.
Removing
Note:
^ Before removing the toothed belt from the camshaft pulley, lock the toothed belt tensioner.
^ 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.
- Drain coolant.
- Unbolt exhaust pipe on turbocharger.
- Disconnect connector on Turbocharger (TC) vane position sensor -G500-.
- Remove cylinder head cover.
- Remove toothed belt from camshaft.
- Install bracket T10014 to cylinder block using tapped hole in vicinity of water pump as shown. Tightening torque: 20 Nm
- Lift engine slightly using spindle - A - until spindle - B - is relieved.
- Remove spindle - B -.
- Before removing cylinder head, extract fuel at tandem pump using hand vacuum pump V.A.G 1390 with bleed receptacle V.A.G 1390/1.
- Remove camshaft pulley hub.
- Pull off/disconnect all other electrical connections/wiring as necessary from cylinder head and lay aside.
- Separate all connections from cylinder head for coolant, vacuum and intake hoses.
Note: Maintain sequence when loosening and tightening cylinder head bolts.
- Loosen and remove cylinder head bolts in sequence.
- Remove cylinder head.
- Check cylinder head distortion once cylinder head sealing surfaces have been cleaned.
Installing
Note:
^ Always replace cylinder head bolts.
^ For repairs, carefully remove gasket remains from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces. When using abrasive paper do not use a grade less than 100.
^ Carefully remove emery and abrasive remains.
^ Thoroughly blow out threaded holes for cylinder head bolts. Place a cloth over the respective hole as a protection against oil etc which may be sprayed out of the hole.
^ Remove the new cylinder head gasket from the packaging just before installation.
^ Handle the gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.
- Check before installing the cylinder head that new cylinder head gasket is identical to old cylinder head gasket (3 possible thicknesses).
- Turn crankshaft to TDC marking before installing cylinder head.
- Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below TDC.
- Position cylinder head gasket.
- Install cylinder head and hand tighten all 10 new cylinder head bolts.
- Tighten cylinder head in four stages in sequence shown as follows:
Stage I = 40 Nm
Stage II = 60 Nm
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Note: Re-torquing the cylinder head after repairs is no longer necessary.
- After tightening cylinder head, turn camshaft so that cam lobes for No. 1 cylinder point equally upward. Before installing toothed belt, turn crankshaft in direction of engine rotation to TDC.
- Install camshaft pulley hub.
- The remainder of the installation is performed in the reverse sequence of removal.
- Road test vehicle and read fault memory.
Checking for distortion
Note: Before installing a cylinder head which has previously been installed, check it for distortion.
Special tools, testers and auxiliary items required
^ Straight edge
^ Feeler gauges
- Position straight edge diagonally over sealing surface (a check in opposite direction must also be made) and determine distortion with feeler gauges.
Max. permissible distortion: 0.1 mm
Note: Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification
Cylinder head gasket identification:
^ Part No. = - arrow 1 -
^ Production control code = - arrow 2 - (can be disregarded)
^ Holes = - arrow 3 -
Note: Different thicknesses of cylinder head gasket are installed depending on the piston projection. When replacing the cylinder head gasket, install a new gasket with the same identification.