Cylinder Head, Removing and Installing

Cylinder head, removing and installing





Special tools and equipment
^ VAG1306 Drip tray
^ VAG1332 Torque wrench (40-200 Nm)
^ VAG1921 Hose clip pliers
^ 3070 Installation tool with guide pins
^ VAS5024 Assembly tool for spring-type clamps

Engines with Polydrive cylinder head bolts:
^ 3452 Tool

Requirements
^ The engine must be no more than warm to touch

Work sequence
- Note safety precautions before starting work.
- Observe rules for cleanliness.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off, disconnect battery Ground strap.
- Remove engine cover.
- Drain coolant.
- Remove secondary air pump motor and bracket.

WARNING:Fuel supply pipes are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Separate fuel supply as well as fuel return pipes at connection on fuel rail. Fuel system is under pressure, therefore place a cloth over connection before hoses are pulled off.
- Seal pipes so that fuel system is not contaminated by dirt etc.
- Remove coolant hose connections on cylinder head.
- Remove inter-connecting, coolant, vacuum and intake hoses on engine.
- Pull connector(s) off ignition coils.
- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
- Remove intake air hose from connection of exhaust turbocharger as follows:
- Pull off hose at pressure regulator valve of crankshaft ventilation.
- Disconnect harness connector at Wastegate Bypass Regulator Valve -N75-.
- Pull off hose at Wastegate Bypass Regulator Valve -N75-.
- Disconnect hose from solenoid valve to turbocharger at bulkhead.
- Disconnect hose between EVAP canister and exhaust turbocharger at bulkhead.
- Pull out securing buckle at connector of exhaust turbocharger and remove air intake hose.





- Remove heat protection pad 1 from air guiding hose 2 (observe installation position).
- Remove air guiding hose 2.
- Loosen 2 bolts from bracket of upper air guiding hose





- Remove heat protection pad from air guiding hose (observe installation position) and loosen clamp 3.
- Remove screws 1 and 4 for heat shield from behind cylinder head.
- Loosen screws 2 and 5.
- Remove air guiding hose, hose to turbocharger and heat shield.





- Remove three exhaust gas turbocharger/exhaust manifold securing bolts -arrows-.
- Remove ribbed belt.
- Remove tensioning element for ribbed belt.
- Remove toothed belt guard (upper part).





- Set camshaft sprocket to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft sprocket must align with arrow on toothed belt guard.
- Mark direction of rotation of toothed belt.
- Remove toothed belt and toothed belt tensioner.
- Turn crankshaft back slightly.
- Loosen pressure piston again and remove threaded pin.
- Remove ignition coils.
- Remove cylinder head cover.





- Loosen socket head bolts in sequence given and then remove completely.

Note: Use tool 3452 for Polydrive cylinder head bolts.

- 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. Damaging will lead to leaks.

- Place a clean cloth in 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 the grade must not be less than 100).
- Carefully remove metal particles, emery remains and cloths.





- Turn crankshaft to TDC No. 1 cylinder.
- Turn crankshaft back slightly.





- Loosen bolts 1 and 2 at bracket for turbocharger approximately 2 revolutions in order to avoid tension when installing cylinder head.





- Center screw guide pins from 3070 into holes for cylinder head bolts 8 and 10.
- Install new cylinder head gasket. Lettering (Part No.) must be readable.
- Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
- Remove guide pins with removal tool from 3070. To do this turn removal tool anti-clockwise, until pins are free.
- Install remaining cylinder head bolts and tighten hand-tight.





- Tighten cylinder head in tightening sequence as follows:
- Pretighten all bolts to 40 Nm.
- Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
- Then tighten all bolts again 1/4 turn (90°) further.

Note: There is no requirement to retighten the cylinder head bolts after repairs.

- Install gasket between turbocharger exhaust manifold and bolt turbocharger as well as bracket to cylinder head.
- Install toothed belt and adjust valve timing.
Filling with new coolant.
The rest of the assembly is basically a reverse of the disassembling sequence.
- Perform work sequence "Procedure after voltage supply open circuit".
If the DTC memory has been erased or the Engine Control Module separated from permanent (battery) positive, the readiness code must be generated again.