Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip tray (VAG 1306) or (VAS 6208)
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Spring type clip pliers (VAS 5024A)
• Polydrive bit and drive socket (T10070) or polydrive key (3452)
• Ignition coil puller (T40039)
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
Removing
• When loosening the cylinder head bolts, the engine must be no more than warm to the touch. Otherwise, the cylinder head may warp.
• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
• Perform a oil change if the engine oil is contaminated
- Release the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.
- Determine whether a coded radio is installed. If necessary, obtain the antitheft code.
- With the ignition off, disconnect the battery cable.
- Remove the plenum chamber bulkhead.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Drain the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the front part of the right wheel housing liner. Remove bolts - 1 through 3 - to do so.
- Remove the catalytic converter with front exhaust pipe. Refer to => [ Catalytic Converter with Front Exhaust Pipe ] Service and Repair.
- Remove the charge air hose - arrow - from the charge air cooler.
- Remove the charge air pipe bolts - arrows - and disconnect the charge air pipe.
- Disconnect all electrical connectors from turbocharger and set aside.
- Remove the oil supply line and coolant supply line bolts - arrows - from the turbocharger.
- Remove the oil return line bolts - arrows - from the turbocharger.
- Remove the turbocharger support bolts - 1 and 2 - and remove the support for the turbocharger.
- Remove battery and battery holder.
- Remove the cover - 1 - for the E-box and remove the wire - 2 -.
- Remove the battery holder bolts - arrows - and remove the battery holder.
- Disconnect the coolant hoses - 1 and 2 -.
- Remove the nut - 1 - and remove the ground wire.
- Disconnect the electrical connector - 2 -.
- Disconnect all electrical connectors required from the cylinder head and set aside.
- Remove the wire bracket bolt - arrow - and set the wiring harness aside.
- Remove the coolant flange bolts - arrows -.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the (T10060A) from the ribbed belt tensioner.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Mark the hoses - 1 through 3 - to the lines.
CAUTION!
The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.
- Open the spring clamps for lines - 1 through 3 - and disconnect the hoses.
- Remove the toothed belt, refer to one of the following:
• => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.
• => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, with Divided Toothed Belt Guard.
- Follow sequence for loosening the cylinder head bolts.
• Verify that all hose and line connections to the engine, transmission and body have been disconnected.
- Remove the cylinder head.
Installing
• The bores in the engine block for the cylinder head bolts must be free of oil and coolant.
• Only remove the new cylinder head gasket from its packing immediately before installing.
• Handle the new gasket with extra care. Damage to the silicon layer and recessed area lead to leakage.
• Replace the cylinder head bolts.
• Always replace self locking nuts and bolts during assembly work.
• Always replace bolts that are secured with tightening specifications as well as O-rings and gaskets.
• After installing a replacement cylinder head with the camshaft installed, oil the contact surfaces between the roller cam followers and cam lubricating surfaces after installing the cylinder head.
- Insert clean cloths into the cylinders 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 the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper below 100 grit).
- Carefully remove metal particles, emery remains and cloths.
- In the event the crankshaft has been rotated in the meantime: Set the cylinder 1 piston to Top Dead Center (TDC) and turn the crankshaft back again slightly.
- Install the new cylinder head gasket. Text (replacement part number) must be visible.
- Note the alignment pins in the cylinder block - arrows -.
- Install the cylinder head.
- Install the cylinder head bolts and tighten them hand tight.
- Tighten the cylinder head bolts in the sequence shown as follows:
- Install the cylinder head cover. Tightening sequence, refer to => [ Cylinder Head Cover Bolt Tightening Sequence ] Service and Repair.
- Install the toothed belt, refer to one of the following:
• => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.
• => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, with Divided Toothed Belt Guard.
- Install battery holder and bolts - arrows -.
- Route the wire - 2 - as shown in the illustration and secure it to the E-box - 1 -.
The rest of the assembly is basically a reverse of the removal sequence.
- Install the battery and follow the necessary measures after connecting the battery.
- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.