Cylinder Head, Removing and Installing

Cylinder head, removing and installing





Special tools, testers and auxiliary items required
^ Guide pins 3070
^ Drip Tray V.A.G 1306 or Drip Tray for VAS 6100 VAS 6208
^ Torque wrench V.A.G 1332
^ Spring-type clip pliers VAS 5024A
^ Polydrive Key 3452 or Polydrive Bit and Drive Socket T10070 (engines with polydrive cylinder head bolts)

Requirements
- The engine must be no more than warm to the touch.

Removing
- Read safety precautions before beginning work on fuel supply system.
- Observe Rules for Cleanliness.
- First, check whether a coded radio is installed. If necessary, obtain anti-theft coding.
- With ignition switched off disconnect battery ground (GND) strap.
- Remove engine cover.
- Drain coolant.

CAUTION! Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Disconnect fuel supply and return lines at connecting point of fuel rail.
- Seal lines so that the fuel system is not contaminated by dirt etc.
- Remove front exhaust pipe from exhaust manifold or turbocharger.
- Disconnect all required connections:
^ Cooling system
^ Crankcase ventilation
^ Secondary air injection (AIR) system
^ Turbocharger/regulation
^ Fuel injection and ignition system
- Remove ribbed belt.
- Remove ribbed belt tensioning element.
- Remove upper toothed belt guard.





- Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with - arrow - on toothed belt guard.
- Remove toothed belt from camshaft gear.
- Turn crankshaft back slightly.
- Remove cylinder head cover.





- Loosen and remove cylinder head bolts in specified sequence.

Note: For polydrive cylinder head bolts, use Polydrive Key 3452 or Polydrive Bit and Drive Socket T10070.

- Carefully lift cylinder head off.

Installing

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

- 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 cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
- Carefully remove metal particles, emery remains and cloths.





- Turn crankshaft to set cylinder 1 at TDC.
- Turn crankshaft back slightly.





- To center, install Guide Pins 3070 in cylinder head bolts 8 and 10.
- Install new cylinder head gasket. Text (replacement part number) must be visible.
- Install cylinder head, insert remaining 8 cylinder head bolts and hand tighten.
- Remove Guide Pins 3070 through bolt holes with guide pin handle. Do this by turning pin handle toward left until pins are free.
- Insert both remaining cylinder head bolts and then fasten them hand-tight.
- Tighten cylinder head in tightening sequence as follows:





- Pre-tighten all bolts to 40 Nm.
- Then tighten all bolts a 1/4 turn (90°) further using a rigid wrench.
- Then tighten all bolts again a 1/4 turn (90°) further.

The rest of the assembly is basically a reverse of disassembling sequence.
- Install toothed belt and adjust valve timing.
- Fill with new coolant.
- Perform "Procedure after interrupting voltage supply".