Removal and Installion
Cylinder head, removing and installing
Special tool workshop equipment, test and measuring appliances and aux. items required
^ 3070 Installation tool with guide pins
^ V.A.G 1306 Drip tray
^ V.A.G 1332 Torque wrench (40 to 200 Nm)
^ VAS 5024 Assembly tool for spring type clamps
Engines with Polydrive cylinder head bolts:
^ 3452 Tool
Prerequisites
^ The engine must be no more than warm to touch.
Work sequence
- Note safety precautions before starting work.
- Observe rules for cleanliness.
- First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Drain coolant.
WARNING! Fuel supply pipes are under pressure! Before removing from hose around file connection. Then release pressure by carefully pulling hose off connection.
- Now separate fuel supply as well as fuel return pipes at connection on fuel rail.
- Seal the pipes so that the fuel system not contaminated by dirt etc.
- Disconnect front exhaust pipe from exhaust manifold or turbocharger.
- Disconnect all necessary connections:
^ Coolant system
^ Cylinder block breather
^ Secondary air system
^ Turbocharger regulation
^ Injection and ignition system
- Remove ribbed belt.
- Remove tensioning element for ribbed belt.
- Remove toothed belt guard-upper part.
- Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must align with arrow on toothed belt guard.
- Take toothed belt off camshaft toothed belt sprocket.
- Turn crankshaft back slightly.
- Remove cylinder head cover.
- Loosen socket head bolts in the sequence given and then remove completely.
Note: Use tool 3452 for Polydrive cylinder head bolts.
- Carefully lift cylinder head off.
Installing
Notes:
^ There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head.
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damaging will lead to leaks.
- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
- Also prevent dirt and emery cloth particles from getting into the coolant.
- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or scratches are formed (when using abrasive paper the grade must not be less than 100).
- Carefully remove metal particles, emery remains and cloths.
- Turn crankshaft to TDC No. 1 cylinder.
- Turn crankshaft back slightly.
- To center screw guide pins from 3070 into holes for cylinder head bolts 8 and 10.
- Install new cylinder head gasket. Lettering (Part No.) must be readable.
- Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
- Remove guide pins with removal tool from 3070. To do this turn removal tool counter clockwise, until the pins are free.
- Install remaining cylinder head bolts and tighten hand-tight.
- Tighten cylinder head in tightening sequence as follows:
- Pretighten all bolts to 40 Nm.
- Then tighten all bolts a 1/4 turn (90°) further using a rigid wrench.
- Then tighten all bolts again a 1/4 turn (90°) further.
The rest of the assembly is basically a reverse of the disassembling sequence.
- Installing toothed belt and adjusting timing.
Filling with new coolant.
- Perform the work sequence "Procedure after voltage supply open circuit".