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Removing and installing cylinder head|Install > < Removing and installing cylinder head

Octavia Mk1

Removing
Removing
  WARNING
Observe measures when disconnecting the battery → Electrical System; Rep. Gr.27.
–  On models fitted with a coded radio set, pay attention to the coding; determine if necessary.
–  Disconnect the battery-earth strap with the ignition off.
–  Remove the noise insulation.
–  Remove air filter with intake hose → 1.9-ltr./74 kW (TDI) Engine - Fuel Injection and Glow Plug System; Rep. Gr.23.
–  Remove battery and battery tray → Electrical System; Rep. Gr.27.
–  Remove pipe at top and the charge air connection pipe → Chapter.
–  Separate connector of the glow plugs.
   
–  Remove front exhaust pipe with catalyst -6- → Chapter.
–  Detach hoses -1- and -2- from turbocharger. First of all, unbolt the charge air pipe from the bracket at the bottom of the engine → Chap. 21-1.
–  Unbolt oil return-flow line at cylinder block -5-.
–  Unscrew support bolt -3-, slacken bolt -4- and tilt the support down.
–  Detach hose -7- from vacuum setting element for charge pressure control.
–  Drain coolant → Chapter.
–  Remove inlet connection from intake manifold and place to the side with hoses connected → 1.9-ltr./74 kW (TDI) Engine - Fuel Injection and Glow Plug System ; Rep. Gr.23.
–  Remove cylinder head cover → Chapter.
–  Use hand vacuum pump and bleeding bottole to extract the fuel through the return-flow hose out of the tandem pump → Chapter.
–  Detach fuel hoses from fuel pipes at cylinder head.
–  Detach coolant hoses from cylinder head.
–  Disconnect the central plug connection for the unit injector valves.
–  Unplug connector for fuel temperature sender -G81-.
–  Unbolt oil feed line at the bracket for oil filter, turbocharger and from the mounts.
–  Unplug connector from coolant temperature sender -G62-.
–  Separate vacuum hose from the tandem pump → Item.
  S21-0022
–  Position the supporting device -MP 9-200- with two hooks -MP 9-200/10-.
–  Support engine with the left hook -A- on the right lifting eye of the cylinder head.
–  Removing timing belt → Chapter.
–  Turn the crankshaft back slightly out of the TDC position
–  Remove camshaft sprocket and hub → Chapter.
–  Removing camshaft position sensor -G40- and toothed belt guard at rear → Chapter.
  S15-0475
–  Screw in the bracket -T10014 - in the front threaded bore of the removed engine console in the engine block in the top part of the coolant pump and support engine with right hook -MP9-200/10- (-B-).
–  Slacken the left hook -MP 9-200/10- (-A-) out of the right lifting eye of the cylinder head.
  S15-0476
–  Slacken cylinder head bolts in the specified order and unscrew.
–  Carefully remove the cylinder head.
  Note
The assistance of a second mechanic is required to remove and install the cylinder head.
  S15-0297

Removing and installing cylinder head|Install > < Removing and installing cylinder head