Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Drip Tray (VAS 6208)

• Retainer (3036)

• Puller (T40001)

• Ignition Coil Puller (T40039)

• Hose Clip Pliers (V.A.G 1921)

• Engine Support Bridge (10 - 222 A)

• Shackle (10 - 222 A /12)

• Locking Pin (T10060A)

• Tooth Belt Tensioner (T10020)

• Polydrive Bit and Drive Socket (T10070)

• Engine Bung Set (VAS 6122)

Removing

• Engine installed.

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

• Perform oil change if engine oil is contaminated.

• If using sealant, note current specifications, refer to the electronic parts catalog ETKA.

- Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.

- Disconnect the electrical connector on the mass airflow (MAF) sensor (G70) - 3 -.






- Open clips - 1 and 2 - and remove air guide hose from MAF sensor.

- Remove front air intake connector on lock carrier - 4 -.

- Remove engine cover.

- Remove air guide hose - arrow - with the (V.A.G 1921).






Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

- Open cap of coolant expansion tank.

- Remove center noise insulation fasteners - 1 to 4 -.






- Remove the right noise insulation - arrows -.






- Remove noise insulation frame - arrow -.






- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Remove electrical connector - arrow - for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.






- Disconnect the coolant line to coolant expansion tank - arrow -.






- Disconnect coolant hose - 1 -.






- Disconnect coolant hose - 2 -.

- Remove Ground (GND) wire nut - 1 -.






- Separate electrical connector - 2 -.

- Disconnect coolant hoses - arrows -.

- Remove the intake manifold.

- Remove the right drive axle heat shield - arrows -.






- Remove nuts - 1 - and - 2 - on oxygen sensor electrical connector bracket under vehicle floor and remove cover.






- Remove bolt - 3 - and free up electrical wiring to oxygen sensor.

- Remove connector coupling from bracket - arrow -.






- Disconnect electrical connector to oxygen sensor (O2S) after three way catalytic converter (TWC) (G130).

- Remove the remaining nuts - arrows - for the front exhaust pipe/turbocharger from below.






- Remove exhaust system bracket and tunnel brace - arrows -.






• Do not bend the flex joint in the front exhaust pipe more than 10° or it could be damaged.

- Disconnect the exhaust system at the clamping sleeve - arrows -.






- Remove front exhaust pipe with catalytic converter and front muffler.

- Remove right drive axle.

- Disconnect air guide pipe - arrow - from charge air cooler.






- Unfasten air duct from turbocharger - arrows -.






- Disconnect the connector - 1 and 2 - and free up the cable.

- Remove bolts - arrows - and remove air guide pipe.






• The illustration depicts the engine removed from behind.

- Unfasten turbocharger oil supply line at cylinder block - 1 -.






- Remove turbocharger oil supply line - 2 -.

- Unfasten turbocharger coolant supply line at cylinder block - 1 -.






- Remove coolant supply line to turbocharger - 2 -.

- Remove the coolant supply line for turbocharger - 3 - at the cylinder block.

- Disconnect oil return line - arrows - on turbocharger.






- Remove bolts - 1 - and - 2 - and remove support for turbocharger.






- Remove the toothed belt. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.

- Loosen the bolt for camshaft sprocket using the (3036).






- Pull off the camshaft sprocket using the (T40001) and claws (T40001/6) and (T40001/7).






- Remove rear toothed belt guard from cylinder head - arrows -.






- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

- Loosen the cylinder head bolts using a (T10070) , paying attention to the sequence of the cylinder head bolts.






• Verify that all hose and line connections between engine, transmission and body have been disconnected.

- Remove cylinder head.

Cylinder Head, Installing

• Tightening specifications and tightening sequence, refer to => [ Cylinder Head Assembly Overview ] Cylinder Head Assembly Overview

• For the correct tightening specifications, refer to => [ Exhaust System Overview ] Removal and Replacement

• Replace the cylinder head bolts.

• Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings.

• Secure all hose connections using hose clamps appropriate for the model type. Refer to the electronic parts catalog ETKA.

• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.

• Carefully remove all grinding and sanding residue.

• Only unpack new cylinder head gasket immediately prior to installation.

• Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.

• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

• Hot bolt paste, refer to the electronic parts catalog ETKA

Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

• Turning over the engine is performed at the center bolt of the crankshaft.

- Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts - arrows - now face toward each other vertically.






- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.

- Set cylinder head gasket in place.

• Pay attention to alignment pins in cylinder block - arrows -.






• Observe cylinder head seal location, identification: Replacement part number must be visible from intake side.

- Set cylinder head in place.

- Insert cylinder head bolts and tighten by hand.

- Cylinder head, tightening sequence. Refer to => [ Cylinder Head Tightening Sequence ] Cylinder Head Assembly Overview.

• There is no requirement to tighten the cylinder head bolts after repairs.

- Install cylinder head cover. Refer to => [ Cylinder Head ] Cylinder Head.

- Install wiper arm.

- Install toothed belt. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Electrical connections and routing.

- Install the intake manifold.

- Air guide pipes with connector, installing. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections with Connector Couplings, Assembling.

- Connect battery.

- Install fuel system.

- Check oil level.

- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

• Only reuse drained coolant if cylinder head or engine block was not replaced.

• Dirty coolant may not be used again.

Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.