Cylinder Head, Removing and Installing

Cylinder head, removing

Special tools, testers and auxiliary items required:

^ Drip tray for workshop crane VAS 6208
^ Counter-holder tool 3036
^ Puller T40001
^ Puller T40039
^ Hose clamp pliers V.A.G 1921

Special tools, testers and auxiliary items required

Pin wrench T10020:

Drift T40098:

Removing
^ Engine installed.

Note:
^ All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
^ If oil is dirty, perform an oil change:
^ When using sealant, observe the current descriptions.

- Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.





- Remove engine cover - arrows -.

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

- Open cap of coolant expansion tank.





- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on sound insulation.





- Loosen quick-release fasteners - 1 - and - 2 - and remove front sound insulation.
- Drain engine coolant
- Remove toothed belt.





- Loosen bolt for camshaft sprocket using counter-holder 3036.





- Pull off camshaft sprocket using two-arm puller T40001 and claw T40001/6 and claw T40001/7.





- Remove rear toothed belt housing from cylinder head - arrows -.





- Disconnect Ground (GND) cable - 1 -.
- Disconnect vacuum line to brake booster at bulkhead - 2 -.
- Disconnect EVAP hose - 3 -.





- Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -
- Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.





- Disconnect electrical connector from Charge Air Pressure Sensor G31 - 1 -.
- Remove left charge air hose - 2 -.





- Remove air duct hose - 1 - to turbocharger at bottom right.
- Remove air duct hose - 2 - to charge air cooler at lock carrier.





- Disconnect connector - 1 and 2 - and free up cable.





- Unfasten oil supply line for turbocharger at cylinder block - 1 -.
- Remove bolt - 2 - of support for turbocharger.





- Remove oil supply line for turbocharger - arrows -.





- Disconnect oil return line - arrows - from turbocharger.





- Loosen support bolt - 1 - for turbocharger by 2 turns.
- Remove intake manifold
- Remove catalytic converter
- Remove cylinder head cover





- Loosen cylinder head bolts, paying attention to sequence of cylinder head bolts.

Note: Verify that all hose and line connections between engine, transmission and body have been disconnected.

- Remove cylinder head.

Cylinder head, installing

Note:
^ Replace cylinder head bolts.
^ Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings.
^ Secure all hose connections using hose clamps appropriate for the model type.
^ Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
^ Thoroughly remove all grinding 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.
^ There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
^ High-temperature lubricant

CAUTION: Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

Note: Turning over the engine is performed at the central bolt of the crankshaft.





- Bring marking on camshaft gear to alignment with marking on toothed belt guard. Recesses - arrows - now point to each other vertically.
- In case the crankshaft was turned in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.





- Set cylinder head gasket in place.
^ Pay attention to centering pins in cylinder block - arrows -.
^ Observe installed position of cylinder head gasket, Marking: Replacement part number must be legible from intake side.
- Set cylinder head in place.
- Insert cylinder head bolts and tighten by hand.





- Tighten cylinder head in sequence indicated, in two stages as follows:
- Tighten with torque wrench:
^ 1. Step: 40 Nm
- Tighten using a solid wrench:
^ 2. Step: 180° (1/2 turn) further (2 x 90° further is permissible)

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

- Install cylinder head cover.
- Install toothed belt.
- Install ribbed belt.
- Electrical connections and routing:
- Install the intake manifold
- Connect battery.
- Bleed fuel system.
- Check oil level.
- Fill with coolant.

Note:
^ Only reuse drained coolant if cylinder head or engine block was not replaced.
^ Dirty coolant must not be re-used.

- Install lock carrier with attachments.





- Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
- Install front bumper cover.
- Check headlight adjustment.

CAUTION: Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.

Torque specifications