- The engine is no more than warm to the touch.
- The pistons should not be at TDC.
Removal the cylinder head
Caution! When performing installation work, especially in the engine compartment due to its tight layout, the following rules must be observed.
- Highways of all types (fuel, hydraulic, fuel vapor recovery systems, coolant, refrigerant, brake fluid, vacuum) and the wires should be arranged in the original order provided by the manufacturer (using appropriate fastening elements).
- To avoid damage to hoses, tubes or wires, ensure adequate clearance when working on all moving or hot parts.
- Check if the car is equipped with a coded radio. In this case, request a security code.
1. With the ignition off, disconnect the battery ground wire.
2. Remove the main timing belt.
3. Remove the distribution hall housing.
4. Remove the roller arm supports together with the arms and place them on a clean surface. At the same time, ensure that during subsequent installation the supports (levers) are in their original places.
5. Open and close the expansion tank cap again to relieve pressure in the cooling system.
6. Then drain the coolant.
7. Loosen the spring clamps and disconnect the cooling system hoses from the thermostat housing.
3. Remove the oil level dipstick guide tube.
Caution! The fuel supply line is under pressure! To avoid injury and fuel contact with skin, wear protective goggles and gloves. Before disconnecting the system elements, the connection point must be wrapped with a rag. Then relieve the pressure by carefully disconnecting the hose.
9. Disconnect the fuel supply line (2). To do this, squeeze the clamps.
10. To prevent contaminants from entering the fuel system, plug the fuel line openings.
11. Disconnect or separate the following parts.
- Hose from the activated carbon canister system to the intake manifold.
- Vacuum hose from brake booster to intake manifold.
- Knock sensor connector (1) (G61) (on the rear of the cylinder block), as well as the connector of the intake manifold pressure sensor (G71) with the intake air temperature sensor (G42).
- Connector from engine speed sensor (G28).
- Connector from coolant temperature sensor (G62), oil pressure sensor (F1) and exhaust gas recirculation valve (N18).
- Throttle control unit connector (J338).
- Injector connectors.
- Connector from heated vacuum valve on oil separator.
- Crankcase ventilation hose on the intake manifold.
- Disconnect any other wires that need to be disconnected from the engine and set them aside.
12. Unscrew the front downpipe from the exhaust manifold.
13. Unscrew the fastening bolt of the rear toothed belt cover in the area of the right hanging eye.
Important! Both lugs are located on the cylinder head, so an additional slinging device must be attached to suspend the engine from the cylinder block.
Engine with the letter designation BSA
The original text can be found on the portal: VWmanual.ru
13. Remove the idler pulley bracket.
Continuation of the description of works for all vehicles
14. Screw the holder into the threaded hole of the idler roller in the cylinder block, as shown in the figure. Tightening torque: 20 Nm.
15. Using the second threaded rod (A), slightly lift the engine to relieve the load on the rod (B).
16. Remove the rod (B).
17. Remove the bracket from the thermostat housing that secures the cooling system pipe to the coolant pump.
18. Loosen and unscrew the cylinder head mounting bolts in the specified sequence.
19. Carefully remove the cylinder head.
Cylinder head installation
Attention!
- There should be no oil or coolant in the threaded holes of the cylinder head mounting bolts located in the cylinder block. Otherwise, when tightening the cylinder head mounting screws, the cylinder block may be destroyed.
- The new cylinder head gasket should only be removed from its packaging immediately prior to installation.
- The gasket must be handled with great care.
1. Prepare new cylinder head mounting screws.
2. Fill the cylinders with clean rags to prevent dirt and abrasive residue from getting between the pistons and the cylinder surface. Also, do not allow contaminants and abrasives to enter the cooling system.
3. Carefully clean the seating surfaces of the cylinder head and cylinder block. Avoid leaving scratches on the mating surfaces.
4. Carefully remove any remaining abrasive and polishing compounds, as well as rags.
5. Bring the piston of the first cylinder to TDC and again slightly turn the crankshaft back.
6. Install a new cylinder head gasket. The inscription on the gasket (part number according to the catalogue) must be visible.
7. Install the cylinder head so that the centering bushings are installed in the corresponding holes.
8. Install new cylinder head mounting screws and tighten them by hand.
9. Tighten the cylinder head mounting screws in the specified sequence (see figure VC2.050) as follows:
- tighten all screws to a torque of 30 Nm;
- tighten the screws by 1/4 turn (90°);
- tighten all screws another 1/4 turn (90°).
Attention: at each stage of tightening, the specified sequence must be strictly followed.
10. Install the roller lever supports in the cylinder head and install the corresponding roller levers on them and on the ends of the valve stems.
11. Install the camshaft housing.
12. Install the main timing belt.
Further installation is carried out in the reverse order of removal.
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