Removal and installation the cylinder head (VW Passat B4)

To remove the cylinder head, disconnect the wires from the battery terminals. Place a container under the engine to collect the coolant, open the expansion tank cap, disconnect the outlet hose from the radiator and drain the coolant. Disconnect the engine cooling system and interior heater hoses from the cylinder head. Disconnect the crankcase ventilation hoses. Disconnect the air duct connecting the fuel metering unit-distributor to the throttle body. Disconnect the throttle drive cable. Disconnect the fuel lines from the injectors. Disconnect the wiring blocks of the sensors and other devices of the fuel injection system, including the coolant temperature sensor, starting injector, etc. Remove the front protective covers of the toothed belt of the camshaft drive.

Remove the upper part of the intake manifold, disconnect the ignition high-voltage wires, remove the cylinder head cover. Loosen the tension roller axle mounting nut, loosen the camshaft drive belt and remove it. Remove the alternator tension bar. Working from underneath the vehicle, loosen the muffler inlet pipe flange mounting bolts to the exhaust manifold. Loosen the cylinder head mounting bolts in the reverse order of tightening the bolts and remove the cylinder head.

To install, turn the crankshaft, set the pistons of the 1st and 4th cylinders to the TDC position. Install the cylinder head gasket with the surface with the inscription "Oben" ("Up") towards the plane of the cylinder head. Turning the toothed pulley of the exhaust camshaft, put a mark on the pulley at the level of the upper plane of the cylinder head, directing it towards the front of the car.

Install the cylinder head on the cylinder block. Tighten the cylinder head mounting bolts, then tighten them. Observing the specified order, tightening torques and tightening angles. Put the toothed belt of the camshaft drive on the pulleys and adjust its tension. as specified above. Install the front protective covers of the camshaft drive belt. Install the upper part of the intake manifold, connect the high-voltage wires. Install the cylinder head cover. Connect the electrical connectors. Connect the fuel lines to the injectors. Install the air duct. Connect the crankcase ventilation hoses. Connect the engine cooling system and interior heater hoses. Install the generator tension bar. Tighten the bolts securing the flange of the muffler inlet pipe to the exhaust manifold. Connect the wires to the battery.