Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Special tools and equipment
^ T10068 Camshaft bar
^ V.A.G. 1306 Drip tray
^ V.A.G 1331 Torque wrench (5...50 Nm)
^ V.A.G 1332 Torque wrench (40...200 Nm)
^ VAS 5024 Assembly tool for spring-type clips
^ AMV 174 004 01 Sealing compound
^ AMV 188 001 01 Sealing compound
Conditions
^ The engine must only be warm to the touch.
Removing
CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing the engine
- Remove engine cover.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove intake manifold, Refer to Timing Cover, Service and Repair.
- Disconnect 4-pin connector -arrow-from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature sensor -G2-.
- Drain coolant.
- Remove coolant thermostat housing, Refer to Thermostat Housing, Engine Cooling, Service and Repair Parts of cooling system, engine side.
- Turn crankshaft on vibration damper securing bolt in engine direction of rotation to TDC cyl. 1 -arrow-.
- Remove cylinder head cover, Refer to Timing Cover, Service and Repair
- Remove camshaft roller chain tensioner -arrow-.
- Disconnect connections from following components on cover:
^ Camshaft Position (CMP) sensor -G40--1-,
^ Camshaft Position (CMP) sensor 2 -G163- -2-,
^ Valve 1 for camshaft adjustment -N205- -3-,
^ Camshaft adjustment valve 1 (exhaust) -N318- -4-.
Note: Mark connector and component before disconnecting.
- Release and free wiring harness.
- Remove camshaft cover, Refer to Timing Cover, Service and Repair.
- Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation).
Note: Do not mark chain with a punched mark, notch or similar!
- Separate front exhaust pipe from exhaust manifold, Refer to Exhaust System, Service and Repair, Exhaust System Components, Servicing
- Check timing settings:
When correctly positioned at TDC cyl. 1, a groove -arrow- can be seen in intermediate shaft chain sprockets
Note: This condition only occurs at every 2nd TDC position.
If the notch cannot be seen:
- Turn crankshaft one full turn further in engine direction of rotation.
Note: When the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand instead of with the chain tensioner.
The camshaft bar T10068 must engage in both shaft grooves.
Note: If the camshaft bar cannot be fitted, turn the crankshaft in engine direction of rotation until approximately 5 mm past the TDC setting for No. 1 cyl. (dependent on drive chain tolerances).
Check setting marks of camshaft timing adjusters with marks on control housing:
Marks -A and B- on camshaft timing adjusters must align with notches -arrows- on control housing -C-.
Distance between tooth -1- and tooth -2- of camshaft timing adjuster must be exactly 16 rollers of camshaft roller chain.
Note: Illustration shows a cover which has been removed.
- First remove exhaust camshaft timing adjuster.
- Remove camshaft timing adjuster together with camshaft roller chain from intake camshaft.
Note: Counter support on camshaft with a 32 mm open jaw spanner -arrow-. Camshaft bar T10068 must not be fitted when loosening or tightening camshaft timing adjuster.
- Remove guide rail securing bolts -arrow- and remove guide rail -1-.
- Place camshaft roller chain to side.
- Loosen socket head bolts in sequence given and then remove.
Note: Use tool 3452 for Polydrive cylinder head bolts.
- Carefully lift cylinder head off.
Installing
- Place a clean cloth into cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
Note: Also prevent dirt and emery cloth particles from getting into coolant.
- Carefully clean cylinder head and cylinder block sealing surfaces. Ensure that no scoring or scratches are formed (when using abrasive paper, grade must not be less than 100).
- Carefully remove metal particles, emery remains and cleaning cloths.
If the piston for No. 1 cylinder is not at TDC:
- Turn crankshaft on vibration damper securing bolt in engine direction of rotation -arrow-.
Note:
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damage will lead to leaks.
- Install new cylinder head gasket. Inscription (Part No.) must be legible.
- Ensure that dowel sleeves are inserted into cylinder block holes 12 and 20 and that cylinder head gasket is seated.
Camshaft bar has been removed:
- Position camshafts in cylinder head to TDC No. 1 cylinder.
Camshaft bar T10068 must engage in both shaft grooves.
Note: If the camshaft bar cannot be fitted, turn engine over (in engine direction of rotation) past TDC No. 1 and then turn back onto TDC No. 1 cyl.
- Fill 3 mm holes in cylinder head gasket with sealing compound AMV 188001 02.
Note: When the cylinder head is installed the holes in the cylinder head gasket are only half visible.
- Install cylinder head, insert new cylinder head bolts and tighten by hand.
- Tighten cylinder head bolts in tightening sequence as follows:
Note: The longer cylinder head bolts must be inserted in the middle holes of the cylinder head.
- Pretighten all bolts to 30 Nm.
- Then tighten all bolts to 50 Nm.
- Then tighten all bolts 1/4 turn (90°) turn further with a rigid wrench.
- Then tighten all bolts again 1/4 turn (90°) further.
The rest of the assembly is basically in reverse order to the disassembling sequence.
Note: Ensure that the O-ring for sealing the oil channel and the seal in the cover are fitted.
- Adjust valve timing, Refer to Timing Cover, Service and Repair.
- Fill with new coolant.
Note: Re-tightening cylinder head bolts after repairs is not required.
- Check camshaft timing adjustments, Refer to Camshaft, Engine, Adjustments