Removal and installation the cylinder head (VW Passat B6)

Removal

Disconnect the gearbox and engine.

Secure the engine to the engine and transmission mount.

Remove the following parts:

• intake manifold;
• lower part of the intake manifold;
• exhaust manifold.

Remove the thermostat housing from the cylinder head.

Remove the EGR valve.

Remove the timing cover.

Remove the camshaft housing.

Remove the roller arms together with the supports and place them on a clean surface.

It is prohibited to interchange roller levers and supports.



Loosen and unscrew the cylinder head mounting bolts in the specified sequence (Fig. 2.42).

Carefully remove the cylinder head.

Installation

Place a clean rag in the cylinders to prevent dirt and sandpaper residue from getting between the cylinder bores and pistons.

Note: Pistons should not be at TDC.

Note: The new cylinder head gasket should only be removed from its packaging immediately prior to installation.

Note: Handle the new gasket with extreme care. Damage to the gasket will result in leaks in the future.

Carefully clean the seating surfaces of the cylinder head and block. Do not leave long scratches or burrs (when using sandpaper, its grain size should be at least 100).



Carefully remove any remaining sandpaper, grit, or rags from the cylinders.

Bring the piston of the first cylinder to TDC and again slightly turn the crankshaft back.

Install a new cylinder head gasket. Marking (part number) should be easy to read.

Install the cylinder head. Pay attention to the centering pins in the cylinder block.

Insert new cylinder head bolts and tighten them hand tight.



Tighten the cylinder head bolts in the sequence shown as follows (Fig. 2.43).

Tighten all bolts to 30 Nm.

Then tighten all the bolts 1/4 turn (90°) with a regular wrench.

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Finally, tighten all the bolts one more time by 1/4 turn (90°).

Insert the bearing elements into the cylinder head and install the corresponding roller levers onto the ends of the valve stems and their bearings.

Install the camshaft housing.

Adjust the valve timing.

Further installation is carried out in the reverse order. In this case, the following must be taken into account

Install the timing cover.

Connect the fuel lines.

Install the EGR valve.