Cylinder Head, Removing and Installing

Cylinder head, removing and installing





Special tools and equipment
^ 3450/2A Head gasket aligner
^ 3450/3 3450/2A complement
^ T10029 Spark plug connector tool
^ VAG1306 Drip tray
^ VAG1331 Torque wrench 5 to 50 Nm (3 7 to 37 ft. lbs.)
^ VAG1332 Torque wrench 40 to 200 Nm (30 to 148 ft. lbs.)





^ VAG1921 Spring clip pliers or VAS5024 Assembly tool for spring-type clip

Requirements
^ Engine must not be hotter than warm to the touch.
^ Pistons must NOT be positioned at TDC.

Work sequence
Observe safety precautions, Refer to Powertrain Management, Fuel Delivery and Air Induction, Service Precautions, Vehicle Damage Warnings
Observe rules of cleanliness, Refer to Powertrain Management, Fuel Delivery and Air Induction, Service and Repair

CAUTION: Obtain radio anti-theft code from customer BEFORE disconnecting battery Ground strap!

- With ignition switched OFF, disconnect battery Ground strap
- Remove engine cover

Note: All cable ties which are opened or cut open to remove the engine, must be replaced in the same position when re- installing the engine.

- Drain coolant.
- Remove intake manifold upper section.

Note: Seal off open portions of lower intake manifold against dirt etc. with clean shop rags.

- Remove hoses from cylinder head using pliers VAG 192 1 or VAS5024.

WARNING: Fuel system is under pressure! BEFORE opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.





- Pull off supply line/hose -1- (with white marking) and return line/hose -2-(with blue marking) at fuel rail connection, and collect fuel that leaks out with a cloth.
- Seal fuel lines so that system is not contaminated by dirt etc.
- Remove air cleaner with intake hose:
- Remove vacuum and pressure lines/hoses for secondary air pump.
- Unbolt and remove secondary air pump motor and bracket.
- Remove front exhaust pipe with catalyst from exhaust manifold, Refer to Exhaust Pipe, Service and Repair
- Remove camshaft drive belt guard upper section.
- Remove ribbed belt
- Remove ribbed belt tensioning element with bracket.





- Set camshaft sprocket to TDC No. 1 cylinder by turning crankshaft.
Mark on camshaft sprocket must align with -arrows- on cylinder head.
- Release tensioning roller and take toothed belt off camshaft sprocket.
- Turn camshaft back slightly.
- Remove cylinder head cover.
- Unscrew upper bolt from rear belt guard.





- Loosen cylinder head bolts in prescribed sequence and then remove completely.
- Carefully lift off cylinder head.

Installing

Note:
^ Always replace cylinder head bolts.
^ There must NOT be any oil or coolant in the bolt pockets in the cylinder head or there is the danger of creating a hydro-lock while tonguing which could lead to structural damage.
^ Only remove the new cylinder head gasket from its packaging immediately before installing.
^ Handle the new gasket with extreme care. Damage will lead to leaks.

- Place a clean cloth over cylinders so no dirt or abrasive particles can get between cylinder wall and piston.
- Take whatever precautions are necessary to prevent dirt and abrasive particles from getting into coolant system. Also prevent dirt and emery cloth particles from getting into coolant.
- Carefully clean cylinder head and cylinder block sealing surfaces, ensuring that no scores or scratches are formed. (When using abrasive paper, grade must NOT be LESS than 100).
- Carefully remove all traces of metal particles, emery remains and cloth.
- If crankshaft has been turned, set cylinder No. 1 piston to top dead center and then turn crankshaft back slightly.





- To centralize, screw guide pins from 3450/2A into front outer holes for cylinder head bolt (as shown).

Note: The tolerance at the upper end of the centralizing holes has been reduced. Therefore, before installing the cylinder head check whether the guide pins can be removed upward. If necessary, grind down the knurling on the guide pins.

- Install new cylinder head gasket.
^ Lettering (part number) must be readable.
- Install cylinder head, screw in 8 remaining head bolts and tighten by hand.
- Unscrew 3450/2A guide pins through bolt holes using 3450/3 pin driver by turning it counter-clockwise until pins are free.
- Install remaining cylinder head bolts and tighten hand-tight.

Cylinder Head Bolt Tightening Sequence:

- Tighten cylinder head in tightening sequence as follows:
- Pretighten all bolts to 40 Nm (30 ft. lbs.).
- Tighten all bolts 1/4 turn (90°) further using a rigid wrench.
- Tighten all bolts a 1/4 turn (90°) further.

Note:
^ When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
^ The rest of the assembly is basically a reverse of the disassembly sequence.

Install camshaft drive belt and adjust timing.
- Install ribbed belt tensioner. Torque: 25 Nm (18 ft. lbs.)
- Install ribbed belt.
- Fill with new coolant.
- Check Diagnostic Trouble Code memory.
Refer to Powertrain Management
- Match Engine Control Module (ECM) to Throttle Control Module.
Refer to Powertrain Management
- Check Readiness code.
- Reset Readiness code after DTC's are corrected, Engine Control Module (ECM) is subject to low voltage with ignition on, or ECM is replaced.