Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Note: The following instructions apply to the left cylinder head.
Removing
- Lock carrier in service position.
- Remove ribbed belt. Refer to Ribbed belt, removing and installing.
- Remove toothed belt. Refer to Toothed belt, removing and installing.
- Remove engine cover (arrows).
- Remove noise insulation panel (arrows).
- Unbolt left and right-side front exhaust pipes from exhaust manifold.
- Unbolt exhaust system from transmission bracket.
- Place VAG1306 drip tray beneath engine.
- Open engine coolant expansion tank cap.
WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly.
- With bumper removed, open coolant drain plug (arrow) on lower left of radiator by turning it counterclockwise. If necessary, attach accessory hose to connection.
- With bumper installed, pull off retaining clamp for lower right radiator hose (from radiator to engine) and disconnect radiator hose from radiator.
- Using 3247 hex ball socket, open coolant drain plug on engine (arrow) as well.
- Unbolt engine coolant expansion tank from bracket and lay aside (remove if necessary).
- Disconnect crankshaft housing ventilation line from cylinder head cover.
- Remove intake air duct between Mass Air Flow (MAF) sensor and intake air elbow.
- Disconnect blue harness connector on Intake Manifold Tuning (IMT) valve.
- Disconnect black harness connector for Intake Air Temperature (IAT) sensor on resonator.
- Cut tie wraps and move wiring to side.
- Disconnect vacuum line at cruise control vacuum diaphragm and at vacuum booster.
- Unbolt cruise control vacuum diaphragm and unhook cruise control vacuum diaphragm linkage at throttle body.
- Disconnect harness connector on throttle body and vacuum lines on fuel pressure regulator.
- Disconnect harness connectors from camshaft adjustment valve and from fuel injectors (arrows).
- Disconnect harness connectors from Engine Coolant Temperature (ECT) sensor and Camshaft Position (CMP) sensor (arrows).
- Cut tie wraps on valve cover.
- Unclip wiring retainer on fuel rail and disconnect crankshaft housing ventilation lines from left and right-side valve covers. Move hoses and wiring clear (to rear).
- Disconnect harness connector for tank diagnostic system in engine compartment at arrow.
- Remove 4 bolts for fuel rail on intake manifold.
- Unclip fuel supply and return lines from retainer.
- Move fuel rail together with fuel injectors aside. Cover fuel injectors with clean cloth.
- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approximately 5 turns.
- Remove 3391 camshaft locator bar.
- Remove camshaft gear using T40001 special tool.
- Disconnect left-side spark plug connectors.
- Unbolt bracket for ignition coils (4 bolts) and move to right side together with ignition coils.
- Unhook accelerator pedal cable and pull up out of retaining bracket.
- Disconnect vacuum line at throttle body and line between vacuum booster and intake air elbow (arrows).
- Remove intake air elbow.
- Remove intake manifold.
- Disconnect heated oxygen sensor harness connector at left side of heater core and set aside.
- Remove left-rear toothed belt guard (arrows).
- Unbolt coolant hose at rear of cylinder head.
- Unbolt coolant hose at front of cylinder head (arrows).
- Using 3452 polydrive special tool, loosen cylinder head bolts in reverse order of tightening sequence and remove.
- Carefully lift off cylinder head.
- When removing and installing, use 3452 polydrive together with normal commercial 10 mm socket.
Installing
Notes:
- Bolt holes in engine block for cylinder head bolts must be free of oil and coolant.
- Always replace cylinder head bolts.
- Vacuum line connections. Refer to Tightening torques.
When installing a new cylinder head:
- Install centering pin for intake manifold.
- Replacement cylinder head may be used to replace left or right cylinder head. Install sealing cap at appropriate front end of replacement cylinder head.
- Coat lip of sealing cap with sealant AMV 188 001 02.
- Using VW295 needle bearing drift press in sealing cap until lip of cap seals with chamfer end of cylinder head.
- Before installing cylinder head, set crankshaft and camshafts to TDC for cylinder 3.
- Install cylinder head gasket onto guide sleeves. Marking "open" or Part No. must face toward cylinder head.
- Install cylinder head, install cylinder head bolts and tighten hand-tight.
- Tighten cylinder head bolts in two stages in sequence shown, as follows:
Stage 1: 60 Nm (44 ft. lbs.)
Stage 2: additional 1/2 turn (180°) using rigid wrench (in two 1/4 turns (90° if necessary).
It is not necessary to re-torque cylinder head bolts again after repairs have been completed.
Sealing contact surfaces between bearing cap and cylinder head.
- Carefully apply small amount of sealant D 454 300 A2 at four end points of sealing surfaces on cylinder head using small screwdriver.
Tightening torques