Volkswagen Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Bracket -T10358-

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

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

Removing

–  Install support device -10 - 222 A- with rack -10 - 222 A /1- as shown and hook into lifting eye. Remove following components: t  Remove air filter housing → Chapter t  Drain coolant → Chapter. t  Remove injectors → Chapter t  Remove intake manifold → Chapter. t  Remove control housing → Chapter t  Remove timing chain and drive chain for oil pump → Chapter t  Remove thermostat housing from cylinder head. t  Remove exhaust manifold with starter catalytic converter.

–  Remove gearbox securing bolt and screw on bracket -T10358- as shown. –  Attach the hooks of support bracket -10 - 222 A- on bracket -T10358- as shown. –  Turn spindle until the hooks are lightly tensioned.

–  Detach hook -1- from left lifting eye and push spindle to left side of support bracket -10 - 222 A-. Remove camshaft housing → Chapter. –  Remove roller rocker fingers together with support elements and lay aside on a clean surface. –  Ensure that roller rocker fingers and support elements are not interchanged.

–  Loosen socket head bolts in sequence given and then remove completely. –  Carefully remove cylinder head. Installing Prerequisite l  The pistons must not be positioned at TDC.   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. –  Now carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby 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. Lettering (Part No.) must be readable. –  Fit cylinder head. When doing this, observe centring pins in cylinder block. –  Insert new cylinder head bolts and tighten hand-tight.

–  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 support elements in cylinder head and fit respective roller rocker finger onto respective valve stem end and support element. –  Install camshaft housing → Chapter. –  Install timing chain and chain drive for oil pump → Chapter –  Adjust valve timing → Chapter. –  Installing valve timing housing → Chapter. Further assembly is basically the reverse of the dismantling procedure.