Cylinder Head, Removing and Installing

Cylinder head, removing and installing

Special tools and equipment





^ VAG1306 Drip tray for VAG1202A
^ VAG1331 Torque wrench (5 to 50 Nm)
^ VAG1332 Torque wrench (40 to 200 Nm)
^ VAG1390 Vacuum pump
^ VAG1390/1 Fluid receptacle
^ T10014 Engine support

Special tools and equipment





^ 1010-222 A/2 Hook

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 hoses/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.

^ Check whether a coded radio is installed. If installed obtain anti-theft coding.
^ With ignition switched off disconnect battery Ground (GND) strap.
^ Remove air cleaner housing with intake hose.
^ Drain coolant.

WARNING:
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen the connection to release pressure.
^ Wear eye and hand protection when performing any type of repair work on the fuel system!

^ Extract fuel from tandem pump.
^ Remove/separate connections for glow plugs, fuel temperature sensor, unit injectors (central connector) and coolant temperature sensor.





^ Remove fuel hoses and coolant hose off lines on cylinder head (arrows).
^ Remove coolant hose -1- and connectors -2- from line union.
^ Remove hose from vacuum reservoir.
^ Remove plenum chamber cover (outer) and plenum chamber sealing part.
^ Separate quick-release coupling on right side at heat exchanger (from exhaust gas heat exchanger).





^ Separate hose connections -1- on non-return valve -3- and to vacuum reservoir.
^ Pull union -2- off brake booster.
^ Separate vacuum hoses for vacuum hoses of bypass flap (AGR cooler), of intake manifold and turbocharger at unions.
^ Remove front exhaust pipe.





^ Disconnect connector -1-.
^ Remove connecting hose -7-.
^ Pull vacuum hose -5- off rear charge air pipe -6-.
^ Separate connecting hose at rear charge air pipe -6- and remove it.
^ Disconnect oil return line -2- from union on cylinder block.
^ Remove bolts -3- and -4- and take off bracket.





^ Disconnect oil supply line at oil filter bracket (arrow) and at coolant pipe.





^ Disconnect oil supply line at exhaust gas turbocharger and exhaust manifold (arrows) and move aside.





^ Remove toothed belt.

Note:
^ Both lifting eyes for the support are located on the cylinder head, an additional bracket for supporting the engine must be secured on the cylinder block.
^ Hook spindle -B- onto cylinder head.

^ Turn crankshaft back slightly.
^ Remove camshaft sprocket hub.
^ Remove toothed belt tensioning roller.
^ Remove coolant pump and idler roller.
^ Remove Camshaft Position (CMP) sensor.
^ Remove rear toothed belt guard.





^ Bolt bracket T10014 in forward threaded hole of removed engine bracket in area of water pump in cylinder block, as shown.
^ Use second spindle -A- and supplementary hook 10-222 A/2, lift engine slightly until spindle -B- is not under tension.





^ Unhook spindle -B- from lifting eye -1- and slide to side.
^ Remove cylinder head cover.





^ Maintain sequence when loosening and tightening cylinder head bolts.
^ Lift cylinder head out with the aid of an assistant.

Installing

Note:
^ Always replace cylinder head bolts.
^ In cases of repair carefully remove gasket remains from cylinder head and cylinder block. Make sure that no long grooves or scratches are created. When using abrasive paper do not use a grade less than 100.
^ Carefully remove emery and abrasive materials.
^ Blow forcibly into the threaded holes for the cylinder head bolts. Place a cloth onto the respective hole for protection against oil splashes.
^ Only unpack new cylinder head gasket and sealant immediately prior to installation.
^ Handle the new gasket with extreme care. Damages to the silicone film and in the depression area will result in leaks.
^ Charge pressure hoses and line connections must be free of oil and grease before reinstalling.

^ Turn crankshaft to TDC marking before installing cylinder head.
^ Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below TDC.





^ Note cylinder head gasket identification.
^ Part No. = arrow -1
^ Control code = arrow -2- (not significant!)
^ Hole(s) = arrow-3

Note:
^ If the cylinder head gasket or the cylinder head are replaced, use a new cylinder head gasket with same number of holes as the old gasket.
^ If components of the crankshaft system have been replaced the new cylinder head gasket must be re-selected by measuring the piston projection in TDC.





^ Install cylinder head sealant.
^ Observe center sleeves (arrows) in cylinder block.
^ Observe head gasket installation position, identification "above" or Part No. must show to cylinder head.
^ Install cylinder head and cylinder head bolts, and tighten by hand.





^ Tighten cylinder head in four stages in sequence shown as follows:
^ 1. Tighten initially with torque wrench:
Stage I = 40 Nm
Stage II = 60 Nm
^ 2. Turn further with normal spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)

Note:
^ It is not necessary to retighten cylinder head bolts after completing the repairs





^ After tightening cylinder head, turn camshaft hub so cam lobes for cylinder No. 1 point evenly upward (arrows).
Install in reverse order.

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of hoses/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.

^ Observe tightening sequence for securing bolts when installing oil return line.
^ Before installing toothed belt, turn crankshaft in direction of engine rotation to TDC and lock in position using crankshaft stop T10050.
^ Perform a road test and check DTC memory.