Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Special tools and equipment
^ V.A.G. 1306 Drip tray
^ V.A.G 1332 Torque wrench (40...200 Nm)
^ VAS 5024 Assembly tool for spring-type clips
^ 3450/2A Guide pins
^ 3450/3 Removal tool
^ 3452 Key
^ T10112 Installation tool
Requirements
^ Engine must only be hand touch warm.
Work sequence
WARNING!
When performing repair work, especially due to the confined conditions in the engine well, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: During the further course of work the battery Ground strap must be disconnected. Check first whether a coded radio is installed. Obtain the radio code if necessary.
^ With ignition switched off disconnect battery Ground strap.
^ Remove engine cover.
^ Drain coolant.
WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
^ Disconnect fuel supply line -1- as well as fuel return line -2- at connection point on fuel rail.
^ Seal lines to avoid contamination of fuel system.
^ Pull hose off EVAP canister solenoid valve.
^ Remove intake manifold upper part.
^ Release all coolant, vacuum and intake hoses from intake manifold/cylinder head as required.
^ Disconnect all electrical wiring as necessary on cylinder head and place to side.
Note: Seal the intake ports in the intake manifold lower section with clean cloths.
^ Disconnect coolant hose at connecting unions.
^ Remove intake and pressure lines for secondary air injection pump.
^ Unbolt and remove secondary air injection pump motor and bracket.
^ Remove front exhaust pipe with catalytic converter.
^ Remove ribbed belt.
^ Remove tensioning element for ribbed belt.
^ Remove bracket on tensioning element for ribbed belt.
^ Remove toothed belt guard - upper part.
^ Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft sprocket must align with arrow on toothed belt guard
^ Release tensioning roller and take toothed belt off camshaft pulley.
^ Turn crankshaft back slightly.
^ Remove upper rear toothed belt guard bolt.
^ Loosen socket head bolts in sequence given using key 3452 and then remove completely.
^ Carefully lift cylinder head off.
Installing
Note:
^ There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head.
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damage will lead to leaks.
^ Place a clean cloth into all cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
^ Also prevent dirt and emery cloth particles from getting into coolant.
^ Carefully clean cylinder head and cylinder block sealing surfaces. Ensure that no scoring or scratches are formed (when using abrasive paper, grade must not be less than 100).
^ Carefully remove metal particles, emery remains and cleaning cloths.
^ If crankshaft has been turned: Set No. 1 cylinder piston to top dead center and then turn crankshaft back slightly.
^ To centralize, screw guide pins from 3450/2A into front outer holes for cylinder head bolts.
^ Install new cylinder head gasket.
^ Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
^ Remove guide pins through bolt holes with extractor 3450/3. Extractor must be turned to left (counter-clock wise) until pins are free.
^ Install remaining cylinder head bolts and tighten hand-tight.
Torque Sequence:
^ Tighten cylinder head bolts in prescribed tightening sequence as follows:
^ Pretighten all bolts to 40 Nm.
^ Tighten all bolts 1/4 turn (90°) further with a rigid wrench.
^ Tighten all bolts again 1/4 turn (90°) further.
The rest of the assembly is basically in reverse order to the removal sequence.
Note: When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
Installing toothed belt and adjusting timing, Refer to Timing Belt, Service and Repair.
^ Install ribbed belt tensioning element and torque to 25 Nm
^ Install ribbed belt.
Filling with new coolant.
^ Check Diagnostic Trouble Code (DTC) memory of engine control module and erase DTC memory if necessary.