Cylinder Head, Removing and Installing
Cylinder Head, Removing and Installing
Special tools, testers and auxiliary items required
• Drip tray (V.A.G 1306) or drip tray for workshop crane (VAS 6208)
• Torque wrench (V.A.G 1332)
• Hose clip pliers VAS 6362
• Guide pins (3450/2 A)
• Complement (3450/3)
• Special wrench (3452) or polydrive bit and drive socket wrench (T10070)
• Pin wrench (T10020)
• Puller (T10112)
Conditions
• The engine must be no more than warm to touch.
Perform the following:
Removing
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Ensure sufficient clearance to all moving or hot components.
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Remove the intake manifold with the fuel rail => [ Intake Manifold with Fuel Rail, Removing and Installing ] Intake Manifold with Fuel Rail, Removing and Installing.
- Remove the coolant hose from the cylinder head.
- Remove the coolant distribution housing => [ (Item 12) Coolant Distribution Housing ] Cooling System Components, Engine Side, Assembly Overview with the coolant hoses.
- Disconnect the heated oxygen sensor (G39) connector on the bulkhead and free up the wiring harness. Refer to => [ (Item 14) electrical connector ] Component Locations Overview.
- Disconnect all other electric wires from the cylinder head and free them up.
- Remove the front exhaust pipe from the exhaust manifold.
- Remove ribbed belt => [ Ribbed Belt, Removing and Installing ] Service and Repair.
- Remove the ribbed belt tensioning damper.
- Remove the upper toothed belt guard.
- Turn the crankshaft the direction of engine rotation and move the camshaft sprocket to TDC cylinder 1.
• The marking on camshaft sprocket must line up with the arrow on toothed belt guard - arrows -.
- Loosen the tensioning roller and remove the toothed belt from the camshaft sprocket.
- Then turn the crankshaft slightly backward.
- Remove the cylinder head cover.
- Remove the upper screw on the rear toothed belt guard.
- Loosen and remove cylinder head bolts in specified sequence.
- Carefully lift cylinder head off.
Installing
• Always replace the bolts.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Only unpack new cylinder head gasket immediately prior to installation.
• Handle new gasket with extra care. Damaging will lead to leaks.
• Stuff clean cloths into cylinder so that no dirt or abrasive powder can get between cylinder wall and piston.
• Do not allow dirt or abrasive powder to get into coolant either.
• Carefully clean the sealing surfaces on the cylinder head and on the cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.
• Carefully remove metal particles, emery remains and cloths.
In the event the crankshaft has been rotated in the meantime:
- Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
- For centering, install the guide pin (3450/2 A) into the front outside holes for the cylinder head bolts.
- Install the new cylinder head gasket.
- Set cylinder head in place.
- Install the remaining 8 cylinder head bolts hand-tight.
- Remove the guide pins through the bolt holes using the bolt screwdriver (3450/3). Do this by turning the extractor toward the left until the bolts are free.
- Install both remaining cylinder head bolts hand-tight.
- Tighten cylinder head in tightening sequence as follows:
Assemble in reverse order of disassembly.
Danger of causing damage to the pistons and the valves.
• When turning camshaft, pistons may not be at TDC for any cylinder.
- Toothed belt, installing => [ Toothed Belt, Removing and Installing ] Service and Repair.
- Install the ribbed belt tensioning element.
Tightening specification: 23 Nm
- Install the ribbed belt. Refer to => [ Ribbed Belt, Removing and Installing ] Service and Repair.
- Install the intake manifold with the fuel rail => [ Intake Manifold with Fuel Rail, Removing and Installing ] Intake Manifold with Fuel Rail, Removing and Installing.
- Connect the battery.
- Fuel System, Bleeding. Refer to => [ Fuel System, Bleeding ] Service and Repair.
- Fill the coolant. Refer to => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Erase the adaptation values and adapt the engine control module to the throttle valve control module. Refer to => Vehicle Diagnosis Tester "Guided Functions".
- Perform a vehicle system test. Refer to => Vehicle Diagnosis Tester "Guided Fault Finding".
- End the vehicle system test in such a way that possibly existing DTC entries are automatically erased.
- Perform road test.
Follow all safety precautions that apply to road tests. Refer to => [ Safety Precautions ] Safety Precautions.
- Perform the vehicle system test once again.
- Correct any faults.