Cylinder Head, Removing And Installing: Removing
- During installation, all cable ties must be installed at the same location.
- Cover the opening of the transmission with a cloth, so that no coolant enters the clutch housing.
Depending on the model preliminary work may be required: CYLINDER HEAD, VALVETRAIN (4-CYLINDER TDI COMMON RAIL 1.6L; 2.0L 4V ENGINE) or appropriate service information .
-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING [CZPB, CZRA] / COOLANT, DRAINING AND FILLING [CZPB, CZRA, DBFB] .
-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .
-- Remove the front exhaust pipe with catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .
-- Bring the engine support and engine mount into the installation position and tighten the bolts to 20 Nm.
-- Remove the Heated Oxygen Sensor -G39-. Refer to HEATED OXYGEN SENSOR, REMOVING AND INSTALLING .
-- Loosen the hose clamp -2-, remove the air duct hose from the charge air cooler.
-- Seal the open lines and connections with clean plugs from the :VAS6122 .
-- Loosen the hose clamp -2-.
-- Free up the coolant hose -3-.
-- Remove the bolts -arrows-.
-- Disconnect the connector -1- from the Charge Air Pressure Sensor -G31-, and remove the right air guide pipe.
-- Loosen the hose clamps -arrows- and remove the coolant hoses.
-- Swing the coolant line -1- to the side.
-- Disconnect the connectors and free up the wires.
1 - For the Oil Pressure Switch -F22- -2-
3 - For the Reduced Oil Pressure Switch -F378- -4-
5 - For the Piston Cooling Nozzle Control Valve -N522- -7-
-- Remove the bolts -arrows-.
-- Remove the bolt -1- and the nut -3- and then remove the support -2- for the intake manifold.
-- Disconnect the connectors:
- For the Throttle Valve Control Module -J338-
- For the Manifold Absolute Pressure Sensor -G71-
- For the Fuel Pressure Sensor -G247-
-- Remove the connector -4- from the bracket.
-- Free up the wiring harness and push to the side.
-- Loosen the hose clamp -1-, remove the air duct hose from the charge air cooler.
-- Free up the wiring harness -1 and 2- from the air duct pipe and transmission.
-- Loosen the screw-type clamp -4-.
-- Remove the bolts -arrows- and remove the air duct pipe.
Vehicles with Secondary Air Injection
-- Disconnect the connector -1-.
-- Squeeze the locking ring on both sides together and remove the connecting hose -2-.
Continuation For All Vehicles:
-- Disconnect the connector -3- for Knock Sensor 1 -G61- from the bracket.
-- Disconnect the connectors -2 and 4-.
-- Disconnect the connectors and free up the wires.
2 - For Coolant Shut-Off Valve -N82-
3 - For Engine Coolant Temperature Sensor -G62-
4 - For Oil Pressure Switch, Level 3 -F447-
-- Remove the bolts -arrows-.
-- Disconnect the connector -1- for the Intake Manifold Runner Control Valve -N316-.
-- Remove the bolts -arrows- and nut -1- and remove the heat shield -2-.
-- Remove the bolt -1-. Just loosen the bolt -3-.
-- Remove the turbocharger bracket -2-.
-- Remove the nuts -arrows-.
-- Remove the turbocharger from the cylinder head and tie up toward the rear.
-- Remove the spark plugs with the :3122B .
-- Remove the bolts -arrows-.
-- Remove the cylinder head bolts with the :T10070 or :T40270 in the sequence -1 through 10-.
- All hoses and line connections must be loosened.
-- Remove the cylinder head.
-- Lay the cylinder head on a soft surface, such as foam.
- Seal the open channels of the intake and exhaust tract with a clean cloth or with completely clean plugs from the :VAS6122 .