Cylinder Head, Removing and Installing

Cylinder head, removing and installing





Special tools, testers and auxiliary items required
^ Guide pins handle 3070
^ Drip tray V.A.G 1306
^ Torque wrench (40 to 200 Nm) V.A.G 1332
^ Hand vacuum pump V.A.G 1390
^ Hand vacuum pump reservoir V.A.G 1390/1

Removing

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

CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.

Note: Before the toothed belt is removed from the camshaft sprocket, lock the toothed belt tensioner.

- Disconnect battery Ground (GND) strap with ignition switched off.
- Remove engine cover.
- Remove connecting pipe between charge air cooler and Motor for intake flap -V157-.
- Pull off fuel supply hose (with white marking) and return hose (with blue marking) from fuel lines (clipped onto bulkhead) and catch any spilled fuel with a shop rag.

Remove sound insulation pan.
- Drain coolant.
- Before removing cylinder head, extract fuel using hand vacuum pump V.A.G 1390 and the hand vacuum pump reservoir V.A.G 1390/1 at tandem pump.
- Pull off/disconnect all electrical wires from cylinder head and set aside.
- Separate all connections, coolant lines and vacuum hoses from cylinder head.
- Remove catalytic converter from turbocharger.





- Remove hub for camshaft sprocket.
- Follow sequence for loosening cylinder head bolts and remove cylinder head.

Note: The cylinder head must be carefully guided to prevent damages.

Installing

Note:
^ Always replace cylinder head bolts.
^ Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sandpaper, the grit may not be less than 100.
^ Thoroughly remove lubrication gel 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.

- Before installing cylinder head, position crankshaft to TDC marking.
- Turn crankshaft against engine running direction until all pistons are approx. at same distance below TDC.
- Set cylinder head gasket in place.

Note: Observe cylinder head gasket identification.





- To center, screw guide pins from 3070 into outer bores on intake side.
- Install cylinder head, insert remaining 8 cylinder head bolts and hand tighten.
- Remove guide pins using guide pin handle from 3070, and then install remaining cylinder head bolts.





- Fasten cylinder head in four steps in sequence shown as follows:
Step I = 40 Nm
Step II = 60 Nm
Step III = 1/4 turn (90°)
Step IV = 1/4 turn (90°)

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

Further installation is performed in reverse order. Note the following:
- After fastening cylinder head turn camshaft sprocket so that lobes for cylinder 1 point upward equally. Before installing toothed belt, set crankshaft to TDC by turning in engine running direction.

Install hub for camshaft sprocket.

Fill with coolant.
- Test drive vehicle and check all Diagnostic Trouble Code (DTC) memories.