Volkswagen Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Guide pins -3070-

t	Diesel injection pump locking pin -3359-

t	Crankshaft stop -T10050-

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Bit XZN 10 -T10385-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Drip tray for workshop hoist -VAS 6208-

Note t  Read-out the anti-theft radio code as the earth strap of the battery has to be disconnected during the next work steps. t  All cable ties which are opened or cut through when cylinder head is removed must be renewed/replaced in the same position when the cylinder head is installed.   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines in their original positions. t  Ensure that there is sufficient clearance to all moving or hot components. Removing –  With ignition switched off, disconnect earth strap from battery. → Electrical system; Rep. gr.27 –  Remove engine cover panel → Chapter. –  Remove air filter housing → Chapter. –  Remove battery and battery holder → Electrical system; Rep. gr.27. –  Remove cowling together with radiator fan -V7- and radiator fan on right of radiator -V35- → Chapter. –  Remove connecting hose on »cold side« → Item from charge air cooler. –  Remove cylinder head cover → Chapter. –  Take toothed belt off camshaft → Chapter.

–  Pull connectors off exhaust gas recirculation valve -N18--1- and off throttle valve module -J338--3-.

–  Unscrew bolts from oil dipstick attachment -arrow- and from connecting pipe for exhaust gas recirculation -2-. –  Remove radiator cowl together with radiator fans → Chapter.

–  Remove securing bolts -arrows- from charge air pipe and separate connector -1- from charge air pressure sender -G31-.

–  Open clamp -2-, lay coolant hose -3- to side and remove charge air pipe. –  Disconnect vacuum line from vacuum pump.

–  Unclip engine pre-wiring harness from retainer -arrow-.

–  Pull off vacuum line -arrow-.

–  Unscrew vacuum line attachment -arrow-. –  Unscrew securing bolts of charge air pipe → Item and pull connecting hose off turbocharger. –  Remove vacuum pump from cylinder head → Chapter.

–  Disconnect connector -arrow- from coolant temperature sender -G62- and guide line out.   Caution Ensure that decoupling element of connecting pipe is not bent and thus stretched. There is a danger of cracking. –  Remove exhaust gas recirculation connecting pipe → Item.   Note The lower bolt on the exhaust gas recirculation cooler can be unscrewed with the Bit XZN 10 -T10385-. –  Remove noise insulation → General body repairs, exterior; Rep. gr.66. –  Drain coolant → Chapter.

–  Loosen securing nuts -arrows- of bracket for diesel particulate filter -A- at crankcase. –  Release connecting clamp between turbocharger and diesel particulate filter.

–  Unscrew securing bolt from bracket on cylinder head -arrow- and push diesel particulate filter to side.

–  Remove connecting pipe -A- to exhaust gas recirculation cooler.   Caution The exhaust gas temperature sender 1 -G235- covers the upper threaded connection of the turbocharger support and must not be bent. It must therefore be removed. –  Remove exhaust gas temperature sender 1 -G235--1-.

–  Unscrew bolt -arrow- from support on turbocharger. –  Pull coolant hoses off coolant connection of cylinder head.

–  Unscrew bolt of oil supply line -arrow- and remove oil supply line. –  Remove camshaft toothed belt pulley and pull off camshaft hub using puller -T10052-.

–  Unscrew securing bolt -arrow- for toothed belt guard. –  Unscrew securing nut of toothed belt tensioning roller.

–  Separate connector for Hall sender -G40--arrow-.

–  Maintain sequence when loosening cylinder head bolts.   Note t  A second mechanic is required for the removal of the cylinder head. t  The toothed belt tensioning roller is pulled off the stud when the cylinder head is lifted out. t  The oil return line of the turbocharger is pulled out of the support when the cylinder head is lifted out. –  First lift cylinder head on gearbox side and guide it out of toothed belt guard. Prevent toothed belt tensioning roller from falling down. –  Place cylinder head down taking care not to bend oil return line. If necessary, place a piece of wood under exhaust manifold. Installing   Note t  Always renew cylinder head bolts. t  In cases of repair, carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. When using abrasive paper do not use a grade less than 100. t  Carefully remove emery and abrasive remains. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. –  Before fitting cylinder head, remove crankshaft stop -T10050- and turn crankshaft opposite direction of rotation until all pistons are nearly uniformly below TDC. –  Cylinder head gasket must lie with identification facing upwards.

–  To centre, screw guide pins -3070- into outer threaded holes on intake side.   Note Tensioning roller must be pushed onto studs when fitting cylinder head. –  Fit cylinder head, install 8 cylinder head bolts and hand-tighten. –  Remove guide pins through bolt holes using removal tool from 3070 and install cylinder head bolts.

–  Tighten cylinder head in 4 stages in sequence shown as follows: 1 -  Tighten initially with torque wrench: Stage I = 30 Nm Stage II = 50 Nm 2 -  Turn further with rigid spanner: Stage III = 90° Stage IV = 90° –  Secure toothed belt rear guard to cylinder head. –  Install hub and camshaft pulley. –  Lock camshaft and high-pressure pump with diesel injection pump locking pin -3359-

–  Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop -T10050-. –  Fit toothed belt → Chapter. Further installation is carried out in the reverse order. In the process, note the following: –  Install cylinder head cover → Chapter. –  Install poly V-belt → Chapter. –  Replenish coolant → Chapter. –  Carry out road test and read event memory → Vehicle diagnostic tester.