Cylinder Head, Removing And Installing

Special tools and workshop equipment required

Instrument/Gauge Tester VAG1306 or Shop Crane - Drip Tray VAS6208
Torque Wrench 1332 40-200Nm VAG1332
Hose Clip Pliers
Head Gasket Alignment Tool - Pins 3450/2A
Head Gasket Alignment Tool - Rod 3450/3
Wrench3452 or Polydrive Bit Drive Socket T10070
Toothed Belt Tensioner T10020
Puller - Spark Plug Connector T10112A

Conditions

The engine must be no more than warm to touch.

Removing

CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
Ensure sufficient clearance to all moving or hot components.

-- Drain the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Remove the intake manifold with the fuel rail, refer to INTAKE MANIFOLD WITH FUEL RAIL, REMOVING AND INSTALLING .

-- Remove the coolant hose from the cylinder head.

-- Remove the coolant distribution housing -item 12- Coolant Distribution Housing with the coolant hoses.

-- Disconnect the connector for the Heated Oxygen Sensor -G39- on the bulkhead -item 14- Connector for Heated Oxygen Sensor -G39- and free up the wiring harness.

-- Disconnect all other electric wires from the cylinder head and free them up.

-- Remove the front exhaust pipe from the exhaust manifold.

-- Remove the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Remove the ribbed belt tensioning damper.

-- Remove the upper toothed belt guard.

-- Turn the crankshaft the direction of engine rotation and move the camshaft sprocket to Top Dead Center (TDC) cylinder 1.

Fig 1: Turning Crankshaft In Direction Of Engine Rotation And Moving Camshaft Sprocket To Top Dead Center (TDC) Cylinder 1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marking on camshaft sprocket must line up with the arrow on toothed belt guard -arrows-.

-- Loosen the tensioning roller and remove the toothed belt from the camshaft sprocket.

-- Then turn the crankshaft slightly backward.

-- Remove the cylinder head cover.

-- Remove the upper bolt on the rear toothed belt guard.

-- Loosen and remove cylinder head bolts in specified sequence.

Fig 2: Cylinder Head Bolts Loosening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully lift cylinder head off.

Installing

NOTE:

Always replace the bolts.

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Only unpack new cylinder head gasket immediately prior to installation.

Handle new gasket with extra care. Damaging will lead to leaks.

Stuff clean cloths into cylinder so that no dirt or abrasive powder can get between cylinder wall and piston.

Do not allow dirt or abrasive powder to get into coolant either.

Carefully clean the sealing surfaces on the cylinder head and on the cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.

Carefully remove metal particles, emery remains and cloths.

In the event the crankshaft has been rotated in the meantime:

-- Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.

-- To center, install the Head Gasket Alignment Tool - Pins3450/2A in the front outer holes for the cylinder head bolts.

Fig 3: Identifying Guide Pins From 3450/2 A & 3450/3 Inserted Into Front Outer Threaded Holes For Cylinder Head Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the new cylinder head gasket.

-- Set cylinder head in place.

-- Install the remaining 8 cylinder head bolts hand-tight.

-- Remove the guide pins through the bolt holes using the Head Gasket Alignment Tool - Rod3450/3. Do this by turning the extractor toward the left until the bolts are free.

-- Install both remaining cylinder head bolts hand-tight.

-- Tighten cylinder head in tightening sequence as follows:

Fig 4: Cylinder Head Bolt Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Step	Tighten
1	-- Using torque wrench, tighten to 40 Nm.
2	-- With a rigid wrench, 90° (¹ /₄ turn) additional turn.
3	-- With a rigid wrench, 90° (¹ /₄ turn) additional turn.

Assemble in reverse order of disassembly.

CAUTION:

Danger of causing damage to the pistons and the valves.

When turning camshaft, pistons may not be at TDC for any cylinder.

-- Install the toothed belt, refer to TOOTHED BELT, REMOVING AND INSTALLING .

-- Install the ribbed belt tensioning element.

Tightening specification: 23 Nm

-- Install the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the intake manifold with the fuel rail INTAKE MANIFOLD WITH FUEL RAIL, REMOVING AND INSTALLING .

-- Connect the battery, refer to Battery, Disconnecting And Connecting .

-- Bleed the fuel system, refer to FUEL SYSTEM, BLEEDING .

-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Erase the adaptation values and adapt the Engine Control Module (ECM) to the throttle valve control module using the Vehicle Diagnostic Tester in "Guided Functions".

-- Perform a vehicle system test using the Vehicle Diagnostic Tester in "Guided Fault Finding".

-- End the vehicle system test in such a way that possibly existing DTC entries are automatically erased.

-- Perform a road test.

Follow all safety precautions that apply to road tests, refer to SAFETY PRECAUTIONS .

-- Perform the vehicle system test once again.

-- Correct any faults.