Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Drip Tray (V.A.G 1306) or Drip Tray for VAS 6100 (VAS 6208)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (V.A.G 1332)

• Spring Type Clip Pliers (VAS 5024 A)

• Polydrive Bit and Drive Socket (T10070)

• Ignition Coil Puller (T40039)


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 fluid and vacuum) and electrical wiring so that the original routing is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

• The engine must be no more than warm to touch.

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

• Do an oil change if the oil is dirty.

- First, check to see if a coded radio is installed. If so obtain the anti-theft code.

- Disconnect the battery ground cable with the ignition turned off.

- Remove the plenum chamber bulkhead.

- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

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

- Remove the left wheel housing liner, front section and the right front wheel housing liner.

- Remove the exhaust pipe with catalytic converter. Refer to => [ Exhaust Pipe with Catalytic Converters ] Service and Repair.

- Reposition the charge air hose clamp - arrow - and disconnect the hose from charge air cooler.






- Remove the bolts - arrows - and remove the charge air pipe.






- Disconnect all electrical wires from turbocharger and set aside.

- Remove the oil supply pipe and the coolant supply pipe bolts - arrows - from the turbocharger.






- Remove the oil return pipe bolts - arrows - from the turbocharger.






- Remove the bolts - 1 and 2 - and the turbocharger support.






- Remove the battery.

- Remove the battery tray bolts - arrows - and tray.






- Remove the coolant hoses - 1 and 2 -.






- Disconnect all electrical wires required from the cylinder head and set aside.

- Remove the wire bracket and set the wiring harness to the side.






- Remove the coolant flange bolts - arrows -.






- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

- Remove the locking pin (T10060 A) from the ribbed belt tensioner.

- Remove the toothed belt. Refer to => [ Toothed Belt ] Service and Repair.

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

- Follow the sequence shown for loosening the cylinder head bolts.






• Verify that all hose and wire connections for the engine, the transmission and the body have been disconnected.

- Remove the cylinder head.

Installing

• 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 packaging immediately before installing.

• Handle the new gasket with extreme care. Damaging will lead to leaks.

• Replace the cylinder head bolts.

- Insert clean cloths into the cylinders so that no dirt or abrasive powder can get between the cylinder wall and piston.

- Do not allow dirt or abrasive powder to get into the coolant either.

- Carefully clean the sealing surfaces on the cylinder head and cylinder block. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).

- Carefully remove any metal particles, emery remains and the cloths.

- In the event the crankshaft has been rotated in the meantime: Set the piston for cylinder 1 to Top Dead Center (TDC) and rotate the crankshaft back again slightly.

- Install the new cylinder head gasket. The part number must be legible.

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






- Set the cylinder head in place.

- Insert the cylinder head bolts and tighten them hand tight.

- Tighten the cylinder head bolt in the sequence as follows:











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

- Install the toothed belt. Refer to => [ Toothed Belt ] Service and Repair.

Further installation is in the reverse order of removal.

Fill with new coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.