Cylinder head
Image of the cylinder head. from the 2nd row (from the left).
1. Cylinder head gasket; installation position: part number facing the cylinder head; after replacement, change the coolant and oil.
2. Cylinder head: Place the removed cylinder head on a plastic pad, otherwise the glow plugs may be damaged; check the curvature of the mating plane: modification of the cylinder head of TDI engines is prohibited; after replacement, change the coolant and oil.
3. Bolt: 23 Nm.
4. Bracket.
5. Engine suspension eye.
6. Bolt: 23 Nm.
7. O-rings: replace.
8. Hollow screw.
9. System tubes. cooling.
10. Bolt.
11. Hollow screw.
12. Sealing rings: replace.
13. Bolt: 23 Nm.
14. Engine suspension eye.
15. Bolt: take into account the sequence when unscrewing; replace.
Cylinder head gasket markings
1. Part number. 2. Holes. The thickness of the cylinder head gasket installed depends on the piston protrusion. If only the cylinder head gasket is being replaced, a new gasket with the same designation as the old one should be used. The left and right cylinder head gaskets cannot be confused; they have different shapes.
Cylinder head - last, and bolt tightening torque
Replace bolts that were tightened with additional tightening.
Tighten the bolts in phase 5 in the specified order:
| Step | Screws | Tightening torque/rotation angle |
| 1 | "1...8" | screw it in by hand until it stops |
| 2 | "1...8" | 35 Nm |
| 3 | "1...8" | 60 Nm |
| 4 | "1...8" | turn 90° |
| 5 | "1...8" | turn 90° |
Removal and installation the cylinder head
Drain the coolant. Remove the turbocharger. Remove the intake manifold. Remove the corresponding camshafts.
Left cylinder head: Remove the coolant hose by loosening the hose clamp "1". Ignore "Pos. 2".
Unscrew bolts "1", remove the system pipe. exhaust gas circulation. "Pos. 2" should not be taken into account.
Unscrew the union nut - arrow on the left - and remove the high-pressure line "1". - Ignore the arrow on the right.
Right cylinder head: Remove the front coolant pipe. Remove the hoses by disconnecting clamp "1" and lifting clamp "2". Ignore the arrows.
Loosen the union nut - arrow on the right - and remove the high-pressure line "1". - Ignore the left arrow.
Unscrew the hollow bolt "arrow".
Unscrew the guide pins "1" of the guide and "2" of the tensioner bar. "T40246" should not be taken into account.
All
Loosen the cylinder head bolts in sequence. "1...8". Loosen the bolts and carefully remove the cylinder head. Risk of damage to the glow plug rods when installing the cylinder head. Do not place the removed cylinder head with the glow plugs installed on the mating surface, as the glow plug rods protrude slightly beyond the mating surface.
Install
Installation in reverse order. Risk of damage to the sealing surface. Carefully remove any remaining sealant from the cylinder head and cylinder block. Avoid creating long scratches or burrs. Risk of damage to the cylinder block. There should be no oil or coolant in the blind holes of the cylinder head bolts. Risk of a leaky cylinder head gasket. Carefully remove any remaining sanding and grinding material. To prevent damage to the silicone layer and the grooves of the cylinder head gasket, handle the gasket with particular care. Risk of damage to open valves. When installing a replacement cylinder head, remove the plastic base to protect the exposed valves only when it comes into direct contact with the cylinder head. There is a risk of damage to the valves and piston crowns after working on the valve train. To ensure that no valve comes into contact with the cylinder head during operation, carefully turn the engine at least 2 revolutions.
Note: Replace bolts that have been over-tightened. Replace self-locking nuts, lip seals, gaskets and seals. rings. Modification of cylinder heads of TDI engines is prohibited. Before installing the replacement cylinder head, it is necessary to lubricate the mating surfaces between the rocker arm and the working surface of the cams with oil. To secure all hose connections, use clamps of the appropriate series. After replacing the cylinder head or cylinder head gasket, it is necessary to completely replace the coolant and oil.
Before installing the cylinder head, the crankshaft and camshafts must be at TDC. Crankshaft "1" is secured at TDC with locking bolt "3242.".
The camshafts are secured with T40060 locating pins. The "arrow" pin in the T40060 locating pin must be positioned perpendicular to the camshaft's axis of symmetry on cylinder bank 1 (right).
The "arrow" pin in the "T40060" installation pin must be positioned perpendicular to the axis of symmetry of the camshaft at cylinder bank 2 (left).
Pay attention to the markings on the cylinder head gasket.
1. Part number/2. Holes
Note: After replacing the cylinder head gasket or cylinder head, select a new cylinder head gasket according to the number of holes in the old gasket. If crankshaft components have been replaced, a new cylinder head gasket should be selected based on the piston protrusion at TDC. Left and right cylinder head gaskets cannot be confused; they have different shapes.
Install the cylinder head gasket. Pay attention to the centering bushes "arrows" in the cylinder block. Cylinder head seal installation position: marked "top" or cylinder head part number.
Install the cylinder head. Tighten the cylinder head bolts. Retightening the cylinder head bolts after repair work is not necessary. Install the front coolant pipe. Install the fuel. high-pressure lines. Installing camshafts. Install the intake manifold. Install the turbocharger. Change the oil. Connect the coolant hose to the union nut. Replace the coolant.
(The original article is available on the website: Audimanual.ru)