1.8L 4-CYLINDER TURBO 5-VALVE Article Text

Transcription

1 1.8L 4-CYLINDER TURBO 5-VALVE Article Text This file passed thru Volkswagen Technical Site - ARTICLE BEGINNING ENGINES 1.8L 4-Cylinder Turbo 5-Valve * PLEASE READ THIS FIRST * NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section. ENGINE IDENTIFICATION Engine identification number is stamped on a machined pad on front of engine block, below cylinder head. See Fig. 1. ENGINE CODES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Code Audi A AEB ATW Volkswagen Passat AEB ATW ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Fig. 1: Locating Engine Identification Number ON-VEHICLE SERVICE THERMOSTAT Removal & Installation WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. 1) Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Drain coolant. See DRAINING COOLING SYSTEM. 2) Thermostat is located at the bottom of water pump housing. See Fig. 3. Remove bolts from thermostat cover, remove thermostat. 3) Clean mating surfaces. Lube new O-ring gasket with coolant. Install thermostat. Tighten thermostat housing bolts to 7 ft. lbs (10 Nm). To install, reverse removal procedure. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING.

2 Fig. 2: Identifying Lower Engine Shield (Noise Insulator) Mounting Points Fig. 3: Identifying Location Of Thermostat & Coolant Drain Plug WATER PUMP CAUTION: Coolant/water mixture should be used at all times. Use only ethylene glycol based (phosphate-free) coolant. NOTE: Water pump is located behind accessary drives, this will require accessory drive belts, generator, P/S pump, fan, pulleys and lower timing belt cover to be removed.

3 Removal & Installation 1) Disconnect negative battery cable. Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Remove complete front bumper assembly. Disconnect all necessary electrical connectors from front of vehicle. 2) Attach Alignment Tools to chassis. Remove bolts securing front of body to vehicle. Slide front of body forward onto alignment tool. This will allow servicing of front engine components. See LOCK CARRIER. 3) Remove accessory drive belts. Drain engine coolant. See DRAINING COOLING SYSTEM. Remove generator. Unbolt power steering pump assembly and set aside with hoses attached. See Fig. 4. 4) Label and remove coolant hoses from water pump. Remove water pump pulley. See Fig. 3. 5) Remove timing belt lower cover (ensure all bolts are removed). Remove mounting bolts and remove water pump assembly. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING. Fig. 4: Identifying Cooling System Components

4 PROGRAMMING NOTE: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. After any repair which required that the battery be disconnected, the following should be performed. Refer to owners manual for additional information. 1) Ensure ignition switch is in OFF position. Reconnect battery positive cable first then connect the negative ground strap. 2) After connecting battery, enter anti-theft code for radio (if equipped). 3) Fully close all power windows, operate each window door switch in up position for at least one second (windows closed) to activate "one touch" opening/closing function (if equipped). 4) Set clock to correct time. ADJUSTMENTS ACCELERATOR PEDAL 1) Remove clip for accelerator pedal cable on throttle body. Depress accelerator pedal to Wide Open Throttle (WOT) position. 2) On manual transmission vehicles, pull sleeve on accelerator pedal cable off curved washer on throttle body until throttle body has opened completely. On automatic transmission vehicles, pull accelerator pedal cable sleeve back to WOT position far enough so throttle has opened completely and kickdown switch audibly clicks. 3) On all vehicles, hold pedal tight in position. Install securing clip for accelerator pedal cable sleeve. Release accelerator pedal. Adjustment is complete. After adjustment, verify WOT position and check idle speed. VALVE CLEARANCE Engine is equipped with non-adjustable, non-serviceable hydraulic valve adjusters. Irregular valve adjuster noise during cranking is normal. If valve adjuster(s) are noisy under any other condition inspect valve adjusters. See HYDRAULIC VALVE ADJUSTERS under REMOVAL & INSTALLATION. TROUBLESHOOTING NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section. REMOVAL & INSTALLATION * PLEASE READ THIS FIRST * CAUTION: Radio/cassette or radio/cd player is equipped with an anti-theft protection circuit. Whenever battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE, and will be inoperative until proper code number is entered. Obtain security code before disconnecting battery. NOTE: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

5 NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on other major assemblies before removal. ACCESSORY DRIVE BELTS CAUTION: If reusing old serpentine or other accessory drive belt(s), mark the running direction of belt with crayon or marker. Reinstalling a used belt in reversed direction could damage the belt, and cause component(s) or engine damage. NOTE: Serpentine belt may also be referred to as ribbed belt or V-belt. For help in identifying accessory drive belt(s) routing and component locations, refer to illustration. See Fig. 5. Removal & Installation (A/C Belt) 1) Raise vehicle, remove lower engine shield (noise insulator). Move lock carrier to service position. See LOCK CARRIER. Loosen 2 mounting bolts at A/C belt tensioner, release tension from belt. 2) Remove belt. To install, reverse removal procedure. Ensure pulleys are free of debris. Using a torque wrench tension belt to 25 Nm (18 ft. lbs). Tighten mounting bolts to 20 Nm (15 ft. lbs). 3) Start engine and check belt running condition. Removal & Installation (Serpentine Belt) 1) Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Move lock carrier to service position. See LOCK CARRIER. Install wrench on ear of serpentine belt tensioner, move clockwise to remove tension off belt. See Fig. 5. Tensioner can be locked into released position by inserting a properly sized Hex wrench into hole in tensioner. 2) Remove belt. To install, reverse removal procedure. Ensure pulleys are free of debris. Belt is automatically tensioned. 3) Start engine and check belt running condition. Removal & Installation (Water Pump Belt) 1) Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Move lock carrier to service position. See LOCK CARRIER. Release tension off serpentine belt. See REMOVAL & INSTALLATION (SERPENTINE BELT). Remove viscous fan with pulley from its bearing. See IVISCOUS FAN (ENGINE COOLING). 2) Using a drift punch to lock up the P/S pump pulley (1), remove fasteners from belt pulley for water pump. See Fig. 6. 3) Remove belt. To install, reverse removal procedure. Ensure pulleys are free of debris. Place belt around P/S pulley then between the 2 halves of the water pump pulley. Slowly go around as you tighten the fasteners (pulleys are also turning). The belt should walk its way out in the pulley groove. Using a torque wrench tighten pulley bolts to 20 Nm (15 ft. lbs). 4) Tension the serpentine belt. DO NOT install fan at this time. Start engine only for a moment to seat the belt and check belt running condition. Turn ignition switch to OFF position. Recheck torque on water pump pulley bolts.

6 Fig. 5: Identifying Accessory Drive Belts & Components Fig. 6: Removing Water Pump Pulley & Belt

7 DRAINING COOLING SYSTEM WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. NOTE: Drain coolant into clean container if coolant is in good condition and is going to be reused. Open cap on engine coolant expansion tank. Remove lower engine shield (noise insulator). Remove lower radiator hose (1). Drain coolant from radiator and hose. Remove drain plug (2) from coolant pump and allow coolant to drain from block. See Figs. 7 and 8. To fill cooling system, see COOLING SYSTEM BLEEDING. Fig. 7: Draining Engine Coolant Courtesy of vag of america

8 Fig. 8: Coolant Hose Connection & Routing Diagram Courtesy of volkwagen of america inc. COOLING SYSTEM BLEEDING 1) Ensure coolant pump drain plug with NEW O-ring and all hoses are secure. See Fig. 7. 2) Install fill adaptor to coolant expansion tank. See Figs. 9 and 10. If special tools are not used, loosen expansion tank and raise about 4 INCHES. Keep in this position while filling. Expose vent hole on heater pipe at firewall connection by pulling back heater

9 hose. See Fig. 11. Fill cooling system through expansion tank until coolant comes out of vent hole. Tighten heater hose and bleed screw. 3) Fill expansion tank to proper level. Install expansion tank cap. Put heater controls in hot position. Start engine and raise engine speed to 2000 RPM for about 3 minutes. Ensure cooling fan operates. Return engine to idle. Check coolant level in expansion tank. Fill as necessary. With engine at normal operating temperature, coolant should be at the Max mark indicated on expansion tank. Once engine has completely cooled, coolant should be at the low mark. Add coolant as necessary. Fig. 9: Installing Fill Adaptor To Coolant Expansion Tank With Large Cap Fig. 10: Installing Fill Adaptor To Coolant Expansion Tank With Small Cap Fig. 11: Locating Heater Hose Vent Hole

10 FUEL PRESSURE RELEASE Remove fuel pump relay from fuse/relay block under left side of instrument panel. Start engine. Allow engine to run until it stops. Turn ignition off. Disconnect negative battery cable. Install fuel pump relay. Slight pressure may remain in system. Before disconnecting any fuel system line, cover connector with a clean shop towel. LOCK CARRIER First Design Remove noise insulation. See Fig. 2. Disconnect intake air ducting located near radiator support. Disconnect headlight and turn signal electrical connectors. Disconnect harness connectors at horns. See Fig. 18. Disconnect coolant fan thermal switch. Disconnect power steering cooling coil. Remove front bumper. Unbolt air guide between lock carrier and air filter on lock carrier. See Fig. 12. Unscrew bolt (No. 3) and replace with support tool (Part No. 3369) onto right and left-hand longitudinal member. See Fig. 13Unscrew bolts (No. 2 and 4) and pull lock carrier in area of support tool (Part No. 3369) forward (moving to service position). To return, reverse procedure. Fig. 12: Identifying Lock Carrier Components (First Design)

11 Fig. 13: Identifying Support Tool (Part No. 3369) Second Design Remove noise insulation. See Fig. 2. Disconnect intake air ducting located near radiator support. Disconnect headlight and turn signal electrical connectors. Disconnect harness connectors at horns. See Fig. 18. Disconnect coolant fan thermal switch. Disconnect power steering cooling coil. Remove front bumper. Unbolt air guide between lock carrier and air filter at lock carrier. See Fig. 14. Remove bolts (No. 5) and replace with guide rods (No. 3411) to right and left longmember. Remove bolts (No. 2 and 3). Lock carrier can be pulled forward approximately 4 INCHES (10 cm) on guide rods (No. 3411). See Figs. 15 and 16. Fig. 14: Identifying Lock Carrier Components (Second Design)

12 Fig. 15: Identifying Guide Rods (Part No. 3411) Fig. 16: Identifying Installed Location Of Guide Rods (Part No. 3411) ENGINE WARNING: ALWAYS release fuel pressure before disconnecting fuel injection related component. DO NOT allow fuel to contact engine or electrical components. NOTE: NOTE: Obtain radio code before disconnecting battery. Remove engine, without transmission, through front of engine compartment. For help in identifying components and component locations, refer to illustrations. See Figs Removal 1) Release fuel pressure. See FUEL PRESSURE RELEASE. Turn ignition on, operate windshield wipers till wiper arms are in the vertical position (pointing up) turn off ignition. Remove battery. Remove lower engine shield (noise insulator). See Fig. 2. Drain engine oil. Drain coolant, see DRAINING COOLING SYSTEM. WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly.

13 2) Remove cover for fuel injectors. Disconnect fuel supply and return lines at fuel rail. See Fig. 17. Disconnect intake air ducting located near radiator support. Disconnect headlight and turn signal electrical connectors. Disconnect harness connectors at horns. See Fig. 18. Disconnect coolant fan thermal switch. Disconnect power steering cooling coil, located at lower left of radiator. Let cooling coil hang free. See Fig. 19. Remove front bumper. See LOCK CARRIER. 3) Remove Motronic Engine Control Module (E-Box) cover and disconnect harness connectors. See Fig. 20 and Fig. 21. Disconnect Kickdown switch harness connector. See Fig. 22. Disconnect Vehicle Speed Sensor (VSS). On Manual Transmission (M/T) disconnect harness connector from transmission (backup lights). Disconnect Anti-Lock Brake System (ABS) harness connectors. See Fig ) Disconnect Oxygen Sensor harness connect, remove fasteners and ground wires and set harness bracket aside. See Fig. 24 and Fig ) Disconnect power steering line clamps on frame and radiator brace. See Fig. 19. Disconnect turbocharger, air intake and throttle valve control module ducts. Disconnect chassis grounds and all electrical connectors, disconnect cables and hoses that would interfere with engine removal. NOTE: DO NOT open the air conditioning refrigerant circuit. Disconnect green electrical connector to A/C compressor. See Fig. 26. Disconnect A/C refrigerant line brackets at support points only. After A/C compressor is removed from bracket, support with wire and set A/C compressor carefully aside, avoid damage from bending or kinking refrigerant lines. 6) Remove left and right side air ducts (4). Remove condenser mounting bolts (1) and (2). Disconnect harness connector (3) for A/C pressure switch. See Fig. 28. Pull condenser up out of its bracket, rotate it to side and use wire to secure it on or near right front wheel. 7) Disconnect front exhaust pipe from exhaust manifold. Disconnect front exhaust pipe from catalytic converter. Remove front catalytic converter from turbocharger. Disconnect harness connectors from around air cleaner box. Remove air cleaner box. See Fig. 27. Disconnect accelerator pedal cable from the throttle valve control module. DO NOT remove locking clip on accelerator pedal cable. See Fig. 30. Disconnect Leak Detection Pump (LDP) vacuum lines. See Fig ) Disconnect all coolant and heater hoses. Remove coolant system expansion reservoir and set aside. See Fig. 29. Remove starter motor. Remove bracket from ATF line from transmission. 9) Remove upper engine-to-transmission bolts. Mark positions of left and right engine mount locating sleeves from bottom. See Fig. 32. Remove lower left and right engine mount nuts. If equipped with automatic transmission, raise vehicle, remove 3 torque converter bolts accessed through starter pinion hole at bell housing. See Fig. 33. Lift engine and transmission slightly using (VAG 1202 A) workshop crane to allow lower engine/transmission connecting bolts to be removed. See Fig. 34. Remove lower engine/transmission connecting bolts. 10) Install Engine Support Bracket (10-222A) and Hooks (10-222A/2) to engine. Install Transmission Support (3147) to transmission bellhousing bolt hole. See Figs. 35 and 36. Carefully raise engine out of vehicle. CAUTION: DO NOT allow torque converter to fall out of bell housing.

14 Fig. 17: Identifying Fuel Lines & Brake Booster Vacuum Hose Fig. 18: Identifying Horns Harness connectors Fig. 19: Identifying Power Steering Cooler Line Mounting Points

15 Fig. 20: Identifying Motronic Engine Control Module (E-Box) Cover Fasteners Fig. 21: Identifying Motronic Engine Control Module (E-Box) With Harness Connectors Removed

16 Fig. 22: Identifying Kickdown Switch Harness Connector Fig. 23: Identifying Anti-Lock Brake System Harness Connectors Fig. 24: Identifying Oxygen Sensor Harness Connector

17 Fig. 25: Identifying Harness Connector Bracket Fig. 26: Identifying A/C Compressor Harness Connector (Green) Fig. 27: Identifying Wastegate, EVAP, Power Output Stage, Mass Air flow Sensor Harness Connectors & Air Box Components Locations

18 Fig. 28: Identifying Location Of A/C Pressure Switch Fig. 29: Identifying Coolant Expansion Tank (Location Of Coolant Level Sensor Connector Not Shown) Fig. 30: Identifying Accelerator Pedal Cable, Cable Flange, Throttle Body Air Intake Duct

19 Fig. 31: Identifying Leak Detection Pump Hose, Remove From Intake Fig. 32: Identifying Location Of Locating Sleeves (Mark Sleeves For Reinstallation) Fig. 33: Identifying Access To Torque Converter Bolts

20 Fig. 34: Using Hoist Crane (VAG 1202 A) To Raise Engine & Transmission Fig. 35: Installing Support Bridge (10-222A) & Trans Support Adaptor (3147) Fig. 36: Installing Engine Sling (2024) & Hoist Crane (VAG 1202 A) Installation 1) To install, reverse removal procedure. Engine alignment

21 adjustment is necessary whenever engine is removed or mounts are loosened. To adjust, loosen through-bolt on engine mount. Loosen transmission mount bolts. Loosen front engine mount and bracket. 2) Lightly rock engine and transaxle to shift as necessary. Evenly tighten mount bolts in reverse order of loosening. Align exhaust so components are free of stress. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS. 3) Adjust accelerator pedal. See ACCELERATOR PEDAL under ADJUSTMENTS. Verify engine fluid levels are filled to proper levels. Adjust clutch pedal (if equipped). CAMSHAFTS CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed. Valve damage may result. NOTE: For help in identifying components and component locations, refer to illustration. See Fig. 37. Removal 1) Remove upper timing belt cover. Remove camshaft cover. Place crankshaft at TDC with No. 1 cylinder on compression stroke. Release tensioner, using Torx T45 bit, loosen bolt (1) at timing belt tensioner. Push timing belt tensioner pulley (2) downward and remove timing belt from camshaft sprocket. See Figs ) Turn crankshaft back slightly. Using Camshaft Holder (3036), remove camshaft sprocket bolt. Remove camshaft sprocket. Remove wood drift key. Install camshaft sprocket bolt and washer until washer is tight against camshaft. 3) Clean camshaft drive chain and chain sprockets. Moving only the cams align the marks on the cam sprocket with arrows on the bearing caps. Using paint, mark chain and sprockets opposite arrows on bearing caps. Distance between both arrows (and between paint markings) is 16 rollers on the chain. See Fig. 39. If a new chain is being installed, distance between Notch "A" and "B" must equal 16 drive chain rollers. Notch "A" is slightly off set inward toward drive chain roller (1). See Fig ) Remove camshaft position sensor housing. Mark installation position on bearing caps with a colored marker. Secure chain tensioner, install Chain Tensioner (3366) and tighten to keep slight pressure on chain between camshafts. DO NOT overtighten chain tensioner. See Fig. 41. Remove camshaft caps as follows: * Remove camshaft intake and exhaust bearing caps No. 3 and 5. Loosen bolts in small amounts evenly in a criss-cross manner. See Fig. 38. * Remove double bearing cap. * Remove both bearing caps at chain sprockets on intake and exhaust camshafts. * Remove chain tensioner securing bolts. * Remove intake and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence. 5) Remove intake and exhaust camshafts with chain tensioner and retainer for chain tensioner (3366) from cylinder head.

22 Fig. 37: Identifying Cylinder Head Components Fig. 38: Identifying Camshafts Bearing Caps 1-5 & Double Bearing Cap

23 Fig. 39: Identifying Marks On Cam Chain Gears & Arrows On Cam Caps Courtesy of volkswagon united states inc. Fig. 40: New Camshaft Drive Chain Install Dimensions

24 Fig. 41: Identifying Usage Of Camshaft Chain Adjuster Retainer Tool Inspection Check camshaft bearing oil clearance. See CAMSHAFT table under ENGINE SPECIFICATIONS. If oil clearance is not within specification, install new camshaft and recheck clearance. If clearance still exceeds specification, replace cylinder head. Check camshaft end play. See VALVE TRAIN under OVERHAUL. CAUTION: If cam followers are charged with oil, allow 30 minutes for followers to bleed down before starting engine. Pistons may strike valves, resulting in bent valves. Installation NOTE: When installing the bearing caps, ensure that the cap markings can be read from the intake side of the cylinder head. 1) Place camshafts in cylinder head. Ensure lobes for No. 1 cylinder are pointed upward. See Fig. 37. Fit drive chain onto both camshafts relative to the marks. Replace chain tensioner rubber/metal gasket and coat shaded area lightly with sealant (D A2). See Fig. 42. Slide chain tensioner between drive chain. NOTE: Take note of dowel sleeves. 2) Oil running surfaces of camshafts. Place camshafts with drive chain in cylinder head. Tighten chain tensioner to 10 Nm (7 ft. lbs). Tighten camshaft bearing caps No. 2 and 4 evenly to 10 Nm (7 ft. lbs). Install both bearing caps at chain sprockets for intake and exhaust camshafts. Ensure camshafts are positioned correctly. Tighten bearing caps to 10 Nm (7 ft. lbs). Remove retainer for chain tensioner (3366). 3) Lightly coat hatched area of double bearing cap with sealant (D A2). See Fig. 43. Install and tighten to 10 Nm (7 ft. lbs.), remember dowel sleeves. 4) Install remaining bearing caps and tighten to 10 Nm (7 ft. lbs.), remember dowel sleeves. Check position of marks made on camshafts sprockets relative to one another (positioning should be close to prior to removal). See Fig. 39. If a new chain is being installed, distance between Notch "A" and "B" must equal 16 drive

25 chain rollers. Notch "A" is slightly off set inward toward drive chain roller (1). See Fig ) To complete installation, reverse removal procedure. If cam followers are charged with oil, allow 30 minutes for followers to bleed down before starting engine. Fig. 42: Applying Sealant (D A2) To Chain Tensioner Mounting Surface Fig. 43: Applying Sealant (D A2) To Double Bearing Cap CAMSHAFT OIL SEALS CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed. Valve damage may result. CAUTION: DO NOT allow camshaft to turn when removing camshaft sprocket bolt. Removal (Exhaust Cam) 1) Remove upper timing belt cover. Place crankshaft at TDC with No. 1 cylinder on compression stroke. Release tensioner, using Torx(R) T45 bit, loosen bolt (1) at timing belt tensioner. Push timing belt tensioner pulley (2) downward and remove timing belt from camshaft sprocket. See Figs ) Turn crankshaft back slightly. Using Camshaft Holder (3036), remove camshaft sprocket bolt. Remove camshaft sprocket. Install camshaft sprocket bolt and washer until bolt comes to a stop (hand tight) against camshaft. See Fig ) Unscrew inner part of (2085) oil seal extractor 2 turns (approx. 3 mm) out of the outer section and lock with knurled screw. Lubricate threaded head of oil seal extractor, place in position and while exerting firm pressure, screw as far as possible into oil seal. See Fig ) Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out.

26 Fig. 44: Camshaft Sprocket bolt Installed In Camshaft Fig. 45: Installing Seal Puller (2085) Installation Coat new seal lip lightly with engine oil. DO NOT oil outer circumference of oil seal. Using guide sleeve (3241/2), slide seal until flush with head. See Fig. 46. Using seal installer with press sleeve (3241/1) and bolt (3241/5), install new camshaft oil seal flush into cylinder head. See Fig. 47. Install CMP sensor. To complete installation, reverse removal procedure. Fig. 46: Installing Guide Sleeve (3241/2) Onto Camshaft

27 Fig. 47: Installing Cam Oil Seal Using Press Sleeve (3241/1) & Bolt (3241/5) Removal (Intake Cam) 1) Remove upper timing belt cover. 2) Unbolt Camshaft Position (CMP) sensor housing. Remove CMP sensor-to-rotor bolt. Carefully pry off rotor. See Fig ) Screw tool (2058/1 bolt) into camshaft. See Fig. 49. Unscrew inner part of (2058) oil seal extractor 2 turns (approx. 3 mm or 0.118") out of outer part and lock with Knurled screw. See Fig ) Lubricate thread head of oil seal extractor, place it in position while applying firm pressure screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted. Fig. 48: Identifying Cam Position (CMP) Sensor Harness Connector

28 Fig. 49: Installing Adaptor (2085/1) Into Intake Camshaft Fig. 50: Installing Seal Puller (2085) Installation Coat new seal lip lightly with engine oil. DO NOT oil outer circumference of oil seal. Using guide sleeve (3241/2), slide seal until flush with head. See Fig. 51. Using seal installer with press sleeve (3241/1) and bolt (3241/3), install new camshaft oil seal flush into cylinder head. See Fig. 52. Install CMP sensor, tighten shutter wheel for sensor to 25 Nm (18 ft. lbs.) and the Camshaft Position (CMP) sensor housing to 10 Nm (7 ft. lbs.). To complete installation, reverse removal procedure. Fig. 51: Installing Guide Sleeve (3241/2) Over Intake Cam

29 Fig. 52: Installing Seal Using Press Sleeve (3241/1) & Bolt (3241/3) CORE PLUG (CYLINDER HEAD) CAUTION: Ensure core plug (sealing cap) is installed in cylinder head. Removal Removal procedure of core plug not provided by manufacturer at this time. Installation Coat outside circumference of core plug (sealing cap) with sealant (AMV ). Using needle bearing drift (VW295), drive in core plug until outside rim is flush with end of chamfer in cylinder head. See Fig. 53. Fig. 53: Identifying Installed Depth Of Core Plug (Sealing Cap) CRANKSHAFT FRONT OIL SEAL NOTE: For help in identifying components and component locations, refer to illustration. See Fig. 54. Removal 1) Remove timing belt. See TIMING BELT. 2) Remove crankshaft toothed belt sprocket, by counterholding sprocket with locking fixture (3099) tool. See Fig. 55. To

30 guide oil seal extractor, screw bolt from tool kit (3083) as far into crankshaft as possible. See Fig ) Unscrew inner part of (2085) oil seal extractor 2 turns (approx. 3 mm) out of the outer section and lock with knurled screw. Lubricate threaded head of oil seal extractor, place in position and while exerting firm pressure, screw as far as possible into oil seal. See Fig ) Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out. Fig. 54: Identifying Cylinder Block Front & Rear Crankshaft Seals

31 Fig. 55: Removing Crankshaft Tooth Timing Belt Sprocket (3099) Fig. 56: Installing Guide Bolt From Tool Kit (3083) Into Crankshaft Fig. 57: Removing Crankshaft Seal With (2085) Installation Lubricate lip of new seal. Place guide sleeve from Seal Installer (3083) onto crankshaft. Push oil seal over guide sleeve. Press seal completely into position with press sleeve (3083). See Figs. 58 and 59. Reinstall crankshaft toothed belt sprocket, by holding sprocket with 3099 tool. See Fig. 55. To complete

32 installation, reverse removal procedure. See TORQUE SPECIFICATIONS. Fig. 58: Installing Guide sleeve From Tool Kit (3083) Onto Crankshaft Fig. 59: Installing Crankshaft Front Oil Seal With Press Sleeve From Tool Kit (3083) CRANKSHAFT REAR OIL SEAL NOTE: NOTE: Crankshaft rear oil seal and carrier are serviced as an assembly. For help in identifying components and component locations, refer to illustration. See Fig. 54. Removal & Installation 1) Remove transmission. For M/T, see appropriate article in CLUTCHES. For A/T, see TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove drive plate (A/T) or dual-mass flywheel (M/T). 2) Remove crankshaft oil seal carrier bolts and remove carrier with oil seal. Lightly oil lip with clean engine oil. Install NEW oil seal with carrier using supplied sleeve. Tighten crankshaft oil seal carrier bolts to 25 Nm (18 ft. lbs). See TORQUE SPECIFICATIONS. CYLINDER HEAD CAUTION: DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must settle or valves may strike pistons. Rotate crankshaft by hand 2 revolutions

33 before starting engine to ensure valves do not strike pistons. Removal 1) Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Label and disconnect electrical connectors and vacuum hoses. Drain coolant. See DRAINING COOLING SYSTEM. Remove cover for fuel injectors, wrap a rag around fuel supply and fuel return lines. Disconnect fuel lines at fuel rail connector. See Fig. 17. Seal fuel line to prevent dirt entry. See Fig ) Disconnect power steering cooling coil located at lower left of radiator. Drain coolant from radiator. See Fig. 7. Disconnect lower radiator hose. 3) Disconnect intake air ducting located near radiator support. Disconnect headlight and turn signal electrical connectors. Disconnect coolant fan thermal switch located near lower coolant hose on left side of radiator. 4) Pull cover for power steering fluid reservoir upward. Disconnect 4 harness connectors located under cover. Disconnect antitheft alarm connector at upper left cowl. Disconnect coolant hose at upper left side of engine. 5) Disconnect both horn connectors. See Fig. 18. Attach Alignment Tools to chassis. Remove bolts securing front of body to vehicle. See LOCK CARRIER. Slide front of body forward onto alignment tool. This will allow servicing of front engine components and facilitate removal of cylinder head. 6) Disconnect both ignition coil power output stages harness connectors. Disconnect EVAP canister purge regulator valve from bracket and disconnect electrical connector. Disconnect wastegate bypass regulator valve electrical connector. Remove intake air duct between air cleaner and turbocharger. See Figs ) Pry rubber sleeve off on air cleaner housing and disconnect Mass Airflow (MAF) sensor electrical connector. Disconnect EVAP canister hose connections. Remove air cleaner. See Fig ) Remove timing belt. See TIMING BELT. Disconnect ignition coils and ground wire from cylinder head valve cover and set aside. Cut cable tie on cylinder head valve cover and set wiring aside. 9) Disconnect crankcase breather hose at wastegate, Disconnect engine coolant temperature sensor on rear of cylinder head. Disconnect accelerator pedal. Disconnect Camshaft Position (CMP) sensor on front of cylinder head. See Fig ) Disconnect coolant expansion tank. Disconnect hoses from left coolant line over intake manifold. 11) Remove intake manifold and manifold support. See INTAKE MANIFOLD. Disconnect coolant line at rear of cylinder head. Disconnect heated oxygen sensor connector at left side of plenum and set aside. Disconnect turbocharger oil and coolant lines and front pipe on top of turbocharger. See TURBOCHARGER. NOTE: When valve cover has been removed, take note of oil deflector positioning. 12) Disconnect oil and coolant lines and front pipe from lower part of turbocharger. Disconnect exhaust system bracket on transmission, then disconnect front pipe from turbocharger. Remove cylinder head valve cover, remove cylinder head bolts using sequence. Loosen head bolts a little at a time, till all bolts are loose. See Fig. 60. Remove cylinder head from vehicle. Inspection Thoroughly clean all gasket mating surfaces. Check cylinder head for warpage. Maximum warpage is.004" (.100 mm). Check minimum cylinder head height and replace cylinder head (if necessary). See

34 CYLINDER HEAD under OVERHAUL, also see CYLINDER HEAD under ENGINE SPECIFICATIONS. Installation CAUTION: If cam followers or camshaft have been removed and followers are charged with oil, allow 30 minutes for followers to bleed down before starting engine. Pistons may strike valves, resulting in bent valves. NOTE: DO NOT reuse antifreeze after replacing cylinder block, cylinder head, head gasket, radiator and/or heater core. 1) Ensure part number on cylinder head gasket faces up. Install gasket on cylinder block. DO NOT use any type of sealant. Align camshaft timing marks and position crankshaft at TDC. See TIMING BELT. 2) Install guide pins (VAG 3070 tool set) in head bolt holes No. 8 and 10. Carefully position cylinder head on cylinder. Install remaining head bolts finger tight. Remove guide pins with guide pin removal tool from (VAG 3070) and install remaining bolts. Tighten cylinder head bolts (in 4 steps) in sequence to specification. See Fig. 61. Also see TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Before installation of valve cover apply a thin layer of sealer (D A2) at the points of valve cover where leakage may occur. See Fig. 62. Fig. 60: Cylinder Head Bolt Loosening Sequence Fig. 61: Cylinder Head Bolt Tightening Sequence

35 Fig. 62: Identifying Location To Apply Sealer Before Valve Cover Installation DRIVE PLATE (A/T) & FLYWHEEL (M/T) NOTE: NOTE: The following procedure is given assuming the transmission has been removed or the engine has been removed for servicing. For flywheel (M/T) pilot needle bearing inspection. See PILOT NEEDLE BEARING (M/T). Removal 1) Mark the position of the drive plate (A/T), also marking the positions of the washer (1) and the shim (2) between the drive plate and the crankshaft flange. See Fig. 63. Loosen the bolts in a cross pattern and remove drive plate or flywheel. Fig. 63: Identifying Washer, Driveplate & Shim

36 Fig. 64: Identifying Location Of Bearing Bushing For Torque Converter Installation 1) Install driveplate or flywheel. See Fig. 63. Using 3 of the old bolts inserted into flange, evenly spaced torque to 30 Nm (22 ft. lbs.) Check dimension "A" at 3 points. Specification is approximately 12.3 mm (0.484 INCHES). See Fig. 65. NOTE: Only one shim of the proper size may be used. Tighten flange bolts in a cross pattern. 2) If specification is incorrect, replace shim to obtain proper dimension. Once specification is attained: install NEW bolts and torque in a criss-cross pattern to 60 Nm (44 ft. lbs.) and 1/4 turn (90ø) further (Additional 1/4 turn can be done in several steps). Fig. 65: Calculating Dimension For Shim Size INTAKE MANIFOLD NOTE: Obtain radio code before disconnecting battery. Remove

37 engine, without transmission, through front of engine compartment. Removal & Installation 1) Remove battery. Remove lower engine shield (noise insulator). See Fig. 2. Drain coolant, see DRAINING COOLING SYSTEM. WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. 2) Remove cover for fuel injectors. Remove bolts securing fuel rail to intake manifold. Remove fuel injectors and rail together and rest aside on a clean shop towel. See Fig ) Disconnect harness connectors from around air cleaner box. Remove air cleaner box. See Fig. 27. Disconnect Cam Position (CMP) Sensor. See Fig. 48. Disconnect accelerator pedal cable from the throttle valve control module. DO NOT remove locking clip on accelerator pedal cable. See Fig. 30. Disconnect Leak Detection Pump (LDP) vacuum lines. See Fig. 31. Disconnect vacuum lines at brake booster. 4) Disconnect coolant hoses at upper coolant line. See Fig. 66. Disconnect upper coolant line at intake line and rear coolant flange at rear of cylinder head. See Fig ) Disconnect crank case ventilation hose (1) at manifold. Remove brace (2). See Fig. 68. Remove oil dipstick, unbolt intake manifold at flange and remove manifold. Block intake ports in cylinder head with clean shop towels. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fig. 66: Identifying Intake Manifold & Fuel Rail Components

38 Fig. 67: Identifying Coolant Pipe Connection At Rear Of Cylinder Head Fig. 68: Identifying Brace & Hose Connected To Intake Manifold EXHAUST MANIFOLD Removal and installation procedures are not available from manufacturer. See TURBOCHARGER. On installation, tighten bolts to specification. See TORQUE SPECIFICATIONS. HYDRAULIC VALVE ADJUSTERS WARNING: ALWAYS release fuel pressure before disconnecting fuel injection related component. DO NOT allow fuel to contact engine or electrical components.

39 CAUTION: DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons. NOTE: Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular valve train noise is normal when starting engine. Checking 1) Start engine and run until cooling fan cycles at least once. Increase engine speed to 2500 RPM for 2 minutes or test drive vehicle and observe valve train noise. If valve train noise is still considered noisy, go to next step. 2) Turn engine off. Remove valve cover. Rotate crankshaft until camshaft lobes point upward on lifter being checked. Using a wooden or plastic wedge, push down on top of lifter. See Fig. 69. Try inserting a.008" (.20 mm) feeler gauge between top of lifter and camshaft. If feeler gauge fits between top of lifter and camshaft, replace faulty lifter. Fig. 69: Placement Of Wedge On Lifter (Push Down) PILOT NEEDLE BEARING (M/T) Removal & Installation 1) Remove transmission. For M/T, see appropriate article in CLUTCHES. Remove flywheel (M/T). 2) Using an appropriate puller, remove pilot needle bearing. See Fig. 70. To complete installation, reverse removal procedure. Use bearing driver (VW 207C) to install pilot needle bearing. See Figs. 71 and 72. For flywheel installation. See DRIVE PLATE (A/T) & FLYWHEEL (M/T).

40 Fig. 70: Removing Pilot Needle Bearing Fig. 71: Installing Pilot Needle bearing Using (VW 207C) Fig. 72: Pilot Needle Bearing Insertion Depth (A=1.5 mm) TIMING BELT CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed. Valve damage may result. Removal

41 1) Disconnect negative battery cable. Remove lower engine shield (noise insulator). See Fig. 2. Remove complete front bumper assembly. Disconnect all necessary electrical connectors from front of vehicle. 2) Remove bolts securing front of body to vehicle. Move lock carrier to service position. Attach Alignment Tools to chassis. Slide front of body forward onto alignment tool. This will allow servicing of front engine components. See LOCK CARRIER. 3) Remove accessory drive belts, see ACCESSORY DRIVE BELTS. 4) Rotate crankshaft by hand to Top Dead Center (TDC). See Fig. 73. Remove crankshaft vibration damper pulley. Remove lower timing belt cover. 5) If timing belt is to be reused, mark direction of rotation on belt. Mark timing belt running direction. Using Torx(R) T45 bit, loosen bolt (1) at timing belt tensioner. Push timing belt tensioner pulley (2) downward and remove timing belt. See Fig. 75. Remove timing belt. Fig. 73: Aligning Crankshaft Timing Mark To Top Dead Center (TDC) Fig. 74: Identifying Accessory Drive Belts & Timing Belt Components

42 Fig. 75: Releasing Tension Off Of Timing Belt Installation 1) Align mark on camshaft sprocket with mark on cylinder head cover and/or timing belt guard. See Fig. 76. Install timing belt. Install lower timing belt cover. Install vibration damper pulley and tighten to specification. See TORQUE SPECIFICATIONS. 2) Using a 2-hole spanner (Matra V159 Pin wrench), rotate camshaft belt tensioner until tensioner piston No. 1 is all the way extended and tensioner piston No. 2 lifts approximately.04" (1 mm). See Fig. 77. Tighten timing belt tensioner Torx(R) screw (just enough to hold tensioner). 3) Using center bolt at crankshaft pulley, rotate crankshaft 2 revolutions in running direction and stop on TDC. Check if upper edge of tensioner piston No. 2 lines up within area "A". See Fig. 78. When tensioner piston No. 2 is within area "A", this corresponds to dimension "D" of " (25-29 mm). Adjust as necessary. 4) If upper edge of tensioner piston No. 2 is within area "B", this is acceptable. If upper edge of tensioner piston No. 2 is within area "C", readjust and/or check belt drive including pulley for wear. If tensioner piston No. 2 is within an acceptable area, tighten Torx screw to specification. See TORQUE SPECIFICATIONS. Once again, rotate crankshaft 2 revolutions in running direction and stop on TDC and recheck. To complete installation, reverse removal procedure. Fig. 76: Aligning Timing Marks

43 Fig. 77: Identifying Tensioner Pistons Fig. 78: Identifying Tensioner Dimensions TURBOCHARGER WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. NOTE: NOTE: Obtain radio code before disconnecting battery. Remove engine, without transmission, through front of engine compartment. Always replace gaskets and self locking nuts. For help in identifying components and component locations, refer to illustrations. See Fig. 79-Fig. 86. Removal & Installation 1) Remove battery. Remove engine cover(s). Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Drain coolant, see DRAINING COOLING SYSTEM. NOTE: DO NOT let hang by hoses, do not open the A/C system. 2) Unbolt A/C compressor, move compressor aside, support with

44 wire. 3) Unbolt turbo support bracket (2), disconnect oil return line (1) from turbo and move aside. Remove ducting from turbo (4 & 5). Remove pressure line banjo fitting (3). See Fig ) Disconnect hose from support for charge air pressure regulator valve. Unbolt bracket for coolant supply line at charge air pressure regulator valve. Remove air intake duct between cowl and air cleaner housing. 5) Disconnect harness connectors from around air cleaner box. Remove air cleaner box. See Fig ) Unbolt crankcase ventilation hose (1). Unbolt oil supply line bolts (3) at heat shield. Remove heat shield (4). Remove sleeve (2) from coolant return hose. Remove turbo return hose at line to turbo. The line remains bolted to turbocharger. Unbolt the oil supply line (7) from turbo. See Fig ) Unbolt catalytic converter from turbo, remove bolts (5) from exhaust manifold. Position turbo to gain access to coolant supply line banjo fitting and remove. Remove turbocharger. NOTE: Before tightening turbocharger, loosely bolt coolant supply line to vacuum diaphragm for air pressure regulator valve. Tighten banjo fitting, then tighten mounting bolts for bracket to proper torque. 8) To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. For help in identifying intake ducting components, vacuum line routing and component locations, refer to illustrations. See Figs

45 Fig. 79: Identifying Exhaust Manifold & Turbocharger Components

46 Fig. 80: Removing Turbocharger (1 of 2) Fig. 81: Removing Turbocharger (2 of 2)

47 Fig. 82: Identifying Intake Ducting & Components (1 of 2)

48 Fig. 83: Identifying Intake Ducting & Components With Charge Air Cooler (2 of 2)

49 Fig. 84: Identifying Charge Air Pressure Control System Component & Vacuum Line Routing (Audi AEB Engine)

50 Fig. 85: Identifying Charge Air Pressure Control System Component & Vacuum Line Routing (Passat AEB Engine)

51 Fig. 86: Identifying Charge Air Pressure Control System Component & Vacuum Line Routing (ATW Engine) VISCOUS FAN (ENGINE COOLING) Removal & Installation 1) Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Move lock carrier to service position. See LOCK CARRIER. Release tension off serpentine belt. See REMOVAL & INSTALLATION (SERPENTINE BELT). 2) Remove viscous fan with pulley from its bearing. Use a drift punch to lock up the coupling/pulley (1). Using an 8 mm hex wrench (2) remove fasteners from viscous coupling, remove coupling and Pulley. See Fig. 87. To remove viscous fan bushing (bearing). See VISCOUS FAN BUSHING (BEARING). or go to next step. 3) To install, reverse removal procedure. Ensure pulleys are free of debris. Bolt coupling/pulley to bracket/bearing, Using a torque wrench, tighten mounting bolts to 45 Nm (33 ft. lbs). 4) Using a torque wrench tighten fan to viscous coupling to

52 10 Nm (7 ft. lbs). 5) Start engine and check viscous fan and belt running condition. Fig. 87: Removing Viscous Fan, Coupling & Pulley VISCOUS FAN BUSHING (BEARING) Removal & Installation 1) Raise vehicle, remove lower engine shield (noise insulator). See Fig. 2. Move lock carrier to service position. See LOCK CARRIER. Release tension off serpentine belt. See REMOVAL & INSTALLATION (SERPENTINE BELT). Remove viscous fan and pulley. See VISCOUS FAN (ENGINE COOLING). 2) With fan and pulley removed, remove circlip (1) from bracket. See Fig. 88. Pull bearing out of bracket using (VAG 3367/3, 3350, and 3301). See Fig ) Press Bearing back into bracket using (VAG 3367/1, 3367/2, 3367/3, and 3301). SeeFig ) To complete install, reverse removal procedure. Ensure pulleys are free of debris. Bolt coupling/pulley to bracket/bearing, Using a torque wrench, tighten mounting bolts to 45 Nm (33 ft. lbs). 5) Using a torque wrench tighten fan to viscous coupling to 10 Nm (7 ft. lbs). 6) Start engine and check viscous fan and belt running condition. Fig. 88: Identifying Location of Bearing & Circlip In Bracket

53 Fig. 89: Removing Bearing From Bracket Fig. 90: Installing Bearing Into Bracket OVERHAUL * PLEASE READ THIS FIRST * CAUTION: DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons. CYLINDER HEAD Cylinder Head Resurfacing Measure cylinder head warpage, measure at several points along gasket surface using straight edge and feeler gauge. See Fig. 91. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. If machining causes cylinder head height to be less than specification, replace cylinder head. When checking dimensions for cylinder head height, measure at (A) through the holes for the head bolts. See Fig. 92.

54 Fig. 91: Checking Cylinder Head For Warpage Fig. 92: Checking Cylinder Head Height Valve Guides Checking NOTE: Intake valve stem diameter differs from exhaust valve stem diameter. Use appropriate valve when measuring valve guide wear. 1) To measure valve guide wear, attach dial indicator to cylinder head. Insert valve into guide until valve stem tip is even with top end of guide. 2) Lightly push edge of valve head against dial indicator tip. Zero dial indicator. Push valve away from dial indicator, in direction opposite of camshaft axis. 3) Maximum allowable deflection is.032" (.8 mm) on intake or exhaust valve. If deflection does not exceed specification, guide is okay. If deflection exceeds specification, recheck using new valve. If deflection still exceeds specification, replace worn guides. See Fig. 93.

55 Fig. 93: Checking Valve Guide Wear Valve Guide Removal NOTE: Hand lap valves check sealing, also check cylinder head sealing surface can be refaced. If a problem is found in either case, valve guides should not be replaced. 1) Set the cylinder support (3361) as soon. See Fig ) Install mounting pins for cylinder head bolts (A) into threaded holes (2) and (3). See Fig ) Install pin (B) into relevant hole for valve angle. Outer inlet valves: 21.5 degrees, center Inlet valve: 15 degrees and exhaust valve: 20 degrees. 4) Press worn valve guides out with drift (3360) from camshaft side. See Fig ) Lubricate new valve guides with oil. Using Valve Guide Installer (3360), press valve guide in cold cylinder head as far as guide will go (until shoulder makes contact) from camshaft side. DO NOT exceed one ton pressure. Using Valve Guide Reamer (3363), ream guides to proper stem-to-guide clearance. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Fig. 94: Identifying Cylinder Head Support Fixture (3361) & Settings

56 Fig. 95: Pressing Valve Guide From Cylinder Head Valves Stem Seals Replacement (Head Installed) 1) Remove camshafts. See CAMSHAFTS under REMOVAL & INSTALLATION. 2) Remove valve lifters and place them with contact surface downward. During removal make sure lifters are not interchanged. 3) Remove spark plugs with spark plug removal tool (3122B). 4) Set piston of relevant cylinder to Bottom Dead Center (BDC). 5) Screw VW pressure hose (653/3) into spark plug thread. See Fig. 96. NOTE: DO NOT remove valve springs at this time. 6) Secure (3362) valve spring compressor to cylinder head with tool securing bolt and position installing tool for compressing valve springs to following positions. Outer intake valves: lower position, Center intake valve: upper position and Exhaust valve: lower position. See Fig ) Connect pressure hose to compressed air system supplying at least 6 bar (87 psi) and remove valve springs. 8) Remove valve stem seals with puller (3364) for valve shaft seal. See Fig. 97. Fig. 96: Installing Air Pressure Hose (653/3) Into Spark plug Hole & Valve Spring Compressor (3362) Onto Cylinder Head.