Cylinder Head, Removing and Installing

Cylinder head, removing and installing

Notes:
^ Replace cylinder Headbolts.
^ Replace self-locking nuts and bolts during assembly work.
^ Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.
^ After installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters and cam lubricating surfaces after installing cylinder head.
^ Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head.
^ When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.
^ If a cylinder head is replaced, a cap must be driven in on the front part of the respective head, Refer to Fig. 3.
^ Cylinder heads with cracks between valve seats or between valve seat and spark plug thread can still be used without loss of service life if the cracks are minute (max. 0.3 mm width) or only the first four threads of a spark plug thread are cracked.





Part I
1. Intake manifold
^ removing and installing, Refer to Intake Manifold,Service and Repair.
2. Resonator
3. 10 Nm
4. O-rings
^ Always replace
5. Fuel return line
6. Fuel supply line
^ Union nut, tighten to 25 Nm
7. Socket
8. 10 Nm
9. Holding plate for solenoid valves
10. Fuel - distributor
11. Air duct
12. 10 Nm
13. O-ring
^ Always replace
14. 10 Nm
15. 10 Nm
^ tighten diagonally in sequence
16. Gasket
^ for intake manifold
^ Always replace





Part II
1. Cylinder head gasket replacing
^ Installation position: Part number to cylinder head
^ Sealing cap (core plug) in cylinder head, installing, Refer to Cylinder Head Installing, See Fig. 3.
^ Installing, Refer to Cylinder Head, Installing
^ After replacing, replace coolant
3. Lifting eye
4. 23 Nm
5. Cylinder head bolt
^ Always replace
^ Follow order of removal, Refer to Cylinder Hear,Removal.
^ ^Follow tightening sequence, Refer to Cylinder Head, Installing.
6. Centering pin
^ for intake manifold
7. Special bolt -10 Nm
^ Follow tightening sequence, Refer to Intake Manifold, Service and Repair.
8. Gasket
^ Replace if damaged or leaking
9. Cap
10. O-ring
^ Always replace
11. Hose of - crankcase housing ventilation
12. Ignition coil
13. Cylinder head cover
^ Left cylinder head cover, removing and installing, Refer to Valve Cover, Service and Repair.
^ Right cylinder head cover, removing and installing, Refer to Valve Cover, Service and Repair.
14. Cylinder head cover gasket
^ Replace if damaged or leaking
15. 10 Nm
16. Rear coolant pipe
17. Combination - valve for secondary air injection (AIR)
18. 10 Nm
19. Gasket
^ Always replace
20. O-ring
^ Always replace





Fig. 1 Cylinder head, checking for warpage
- Using straightedge and feeler gauge, check cylinder head for warpage at multiple points.
^ Maximum permissible warpage: 0.1 mm





Fig. 2 Cylinder head refacing dimension
- Refacing cylinder head can only be done to minimum dimension -a-.
^ Minimum dimension: a = 139.25 mm





Fig. 3 Sealing cap (core plug) in cylinder head, installing
Special Tools and Equipment
^ VW295 needle bearing drift

Cylinder heads, which are supplied as replacement parts can be used on left or right and a cap must be installed on the respective front side.
- Coat lip of sealing cap with sealant.
^ Sealant
Refer to Parts Supplier
- Drive sealing cap flush into cylinder block using VW295 needle bearing drift.