Volkswagen Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Guide pins -3450-

t	Bracket -T10358-

t	Torque wrench (5…50 Nm) -V.A.G 1331-

t	Torque wrench (40…200 Nm) -V.A.G 1332-

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

Prerequisites l  The engine must be no more than warm to touch. Removing

–  Install support bracket -10 - 222 A- with rack -10 - 222 A /1- as shown and hook into lifting eye -arrow-. –  Remove valve timing housing → Chapter. –  Remove coolant pump pulley.

–  Unscrew securing bolt for gearbox and attach bracket -T10358- as shown. –  Attach hooks of support bracket -10 - 222 A- to bracket -T10358- as shown. –  Turn spindle until the hooks are lightly tensioned.

–  Unhook hook -1- from left lifting eye and push spindle onto left side of support bracket -10 - 222 A-. –  Remove intake manifold → Chapter. –  Remove roller chains → Chapter. –  Remove cylinder head cover. –  Remove fuel rail complete with all injectors from the cylinder head. –  Disconnect all connection, coolant, vacuum and intake hoses from cylinder head. –  Detach front exhaust pipe from exhaust manifold .

–  Loosen cylinder head bolts in sequence given and then remove completely. –  Carefully remove cylinder head. Installing   Note t  Do not remove new cylinder head gasket from its packing until immediately before installing. t  Handle new gasket with extreme care. Damage will cause leakage. –  Place clean cloths 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 coolant. –  Now carefully clean sealing surfaces of cylinder head and cylinder block. When doing this, ensure that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100). –  Carefully remove metal particles, emery residue and cloths. –  Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly.

–  Fit new cylinder head gasket onto centring bushes -A-. Inscription (Part No.) -B- must be readable. –  Fit cylinder head, install the 8 cylinder head bolts and tighten by hand.

–  Tighten cylinder head bolts in tightening sequence as follows: –  Tighten all bolts to 30 Nm. –  Then tighten all bolts 1/4 turn (90°) further using a rigid wrench. –  Then tighten all bolts again 1/4 turn (90°) further. –  Install roller chains → Chapter.   Note When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns. –  Adjust valve timing → Chapter. Further assembly is basically the reverse of the dismantling sequence. –  Replenish coolant → Chapter.