Contents: Removal ↓ Installation ↓
Removal
1. Remove the engine cover.
2. Drain the coolant.
3. Remove the intake manifold.
4. Unscrew the screws securing the cooling system distributor (arrows).
5. Disconnect the cooling system hose (arrow) from the vapor lock bleed nipple on the rear side of the cylinder head.
6. Disconnect all electrical wires that need to be disconnected from the cylinder head and set them aside.
7. Loosen the bolts securing the exhaust pipe bracket (arrows).
8. Disconnect the exhaust pipe from the exhaust manifold and remove the exhaust pipe.
9. Remove the poly V-belt.
10. Remove the upper part of the timing belt cover.
11. Rotate the crankshaft to set the camshaft toothed pulley to the TDC position of the first cylinder. The mark on the camshaft toothed pulley must match the arrow on the timing belt cover,
12. Loosen the tension roller mounting nut and remove the toothed belt from the camshaft pulley.
13. Remove the tension roller mounting nut and washer.
14. After this, turn the crankshaft back a little.
15. Remove the camshaft timing pulley.
16. Remove the prismatic key from the camshaft.
17. Loosen the rear timing belt cover mounting bolts (arrows).
18. Remove the valve cover.
19. Loosen and unscrew the cylinder head mounting screws in the specified sequence using a wrench.
20. Slightly lift the cylinder head and remove it from the engine by passing it around the timing belt cover from the side (not from above).
Attention!
- The tension roller remains lying on the engine mount bracket.
- The cylinder head must be handled with great care to prevent damage.
Installation
1. There should be no oil or coolant in the threaded holes of the cylinder head mounting bolts located in the cylinder block.
2. The new cylinder head gasket should be removed from the packaging immediately before installation.
Attention!
- The gasket must be handled with great care.
- Replace the cylinder head mounting screws with new ones.
- Fill the cylinders with clean rags to prevent dirt and abrasive residue from falling into the cylinders.
- Also, do not allow contaminants and abrasives to enter the cooling system.
3. Carefully clean the mating surfaces of the cylinder head and cylinder block. It is not permissible to leave scratches on the mating surfaces.
(The original information is posted on the website www.VWMANUAL.ru)
4. Carefully remove any remaining abrasive and polishing compounds, as well as rags.
5. If the crankshaft turned after removing the cylinder head, set it back to the TDC position of the first cylinder and turn it back slightly.
6. For centering, install the guide pins (1) into the outer holes on the exhaust manifold side.
7. Install a new cylinder head gasket. The inscription on the gasket (part number according to the catalogue) must be visible.
Attention! When installing the cylinder head, the tension roller must be installed on the stud.
8. Install the cylinder head, insert and tighten the remaining 8 cylinder head mounting screws by hand.
9. Unscrew the guide pins using a stud wrench.
10. Insert the two remaining cylinder head mounting bolts and tighten them by hand.
11. Tighten the cylinder head mounting screws in the sequence shown as follows.
Caution! The crankshaft must not be at TDC when the camshaft is rotating. Damage to the valves and piston crowns may occur.
12. Install the timing belt and adjust the valve timing.
13. Install the poly V-belt.
Further installation is carried out in the reverse order of removal.
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