Note: Do not remove plastic covers protecting exposed valves until immediately before installing cylinder head. Replace cylinder head bolts.

Transcription

1 Стр. 1 из Cylinder head Note: If a replacement cylinder head is installed, several contact surfaces between support elements, roller cam follower and cam lubricating surfaces of camshaft must be oiled before installing the cylinder head cover. Do not remove plastic covers protecting exposed valves until immediately before installing cylinder head. Replace cylinder head bolts. When replacing cylinder head or cylinder head gasket, coolant must be completely replaced. Cylinder head, assembly overview assembly overview 15-1, Cylinder head, Cylinder head, removing and installing head, removing and installing Toothed belt, removing and installing removing and installing 15-1, Cylinder 15-1, Toothed belt, Compression, checking checking 15-1, Compression pressure, Cylinder head, assembly overview

2 Стр. 2 из Nm Cylinder head cover Tightening sequence 15-1, Tightening sequence cylinder head cover Gasket Replace if damaged or leaking Valve housing Oil filler cap Gasket Replace if damaged or leaking

3 Стр. 3 из 30 4 Nm Cylinder head cover gasket Replace if damaged or leaking Vacuum pump 4 Nm Camshaft Adjustment Valve 1 N205 Removing and installing 15-2, Camshaft Adjustment Valve 1 N205, removing and installing Seal Replace 10 Nm Cable bracket Seal Replace if damaged or leaking 10 Nm Housing Gasket Replace Transport strap 25 Nm 10 Nm Stud bolt for intake manifold Separation plate Cylinder head gasket

4 Стр. 4 из 30 Replace Note installation position: Part Number, to cylinder head 10 Nm Camshaft Position (CMP) Sensor G40 Seal 10 Nm Stud bolt for tensioning roller 20 Nm Stud bolt for exhaust manifold Cylinder head bolt Replace Follow order for loosening and tightening 15-1, Cylinder head, removing and installing Tightening torque: 40 Nm plus an additional 1 / 2 turn (180 ) Check cylinder head for warpage

5 Стр. 5 из 30 - Using straightedge and feeler gauge, check cylinder head for warpage at multiple points. Maximum permissible warpage: 0.1 mm Cylinder head cover, removing and installing Special tools, testers and auxiliary items required Spring type clip pliers VAS 5024 A Puller T40039 Removing - Remove engine cover 24-1, Air filter/engine cover, removing and disassembling.

6 Стр. 6 из 30 - Remove bolts - arrows -. - Remove ignition coils with power output stage 28-1, Ignition coils with power output stage, removing and installing. - Disconnect EVAP line from engine head cover Remove valve housing from cylinder head cover - arrows -. - Remove line for crankcase ventilation with heat shield from turbocharger Disconnect EVAP canister line to turbocharger from cylinder head cover

7 Стр. 7 из 30 - Loosen cylinder head cover from outside toward the inside. - Remove cylinder head cover. Installing Installation is in reverse order of removal, note the following: Note: Replace cylinder head cover gaskets if damaged. - Gently tighten bolts of cylinder head cover from inside working toward outside in several stages. - Verify toothed belt cover is installed properly. Tightening sequence cylinder head cover Tightening torques Component Nm Cylinder head cover to cylinder head 10 Toothed belt guard to cylinder block 10 1) 1) Insert with locking fluid Cylinder head, removing and installing

8 Стр. 8 из 30 Special tools, testers and auxiliary items required Drip tray V.A.G 1306 Puller T40039 Spring type clip pliers VAS 5024A Socket insert T10070 or Polydrive key 3452 Torque wrench V.A.G 1332 Torque wrench V.A.G 1331

9 Стр. 9 из 30 Caution! Observe the following for all installations, especially in engine compartment due to lack of room: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components. Cylinder head, removing Cylinder head, installing 15-1, Cylinder head, removing 15-1, Cylinder head, installing Cylinder head, removing Engine must not be hotter than lukewarm. Note: All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. If engine oil is contaminated, perform oil change. - Determine whether a coded radio is installed. In this case, determine anti-theft coding. - With ignition switched off, disconnect Battery Ground (GND) strap Repair Manual, Electrical Equipment, Repair Group 27, Battery, disconnecting and connecting. - Remove plenum chamber facing wall Repair Manual, Body Exterior, Repair Group 50, Plenum chamber bulkhead

10 Стр. 10 из Remove intake manifold 24-1, Intake manifold, removing and installing. - Drain coolant 19-1, Coolant, draining and refilling. - Remove noise insulation at right. - Remove catalytic converter with front exhaust pipe 26-1, Catalytic converter with front exhaust pipe, removing and installing. - Remove bolts - arrows - and remove air guide pipe. - Pull off/disconnect all electrical wires from turbocharger and set aside.

11 Стр. 11 из 30 - Remove oil supply line and coolant feed line from turbocharger - arrows -. - Remove oil return line - arrows - from turbocharger. - Remove bolts and and remove support for turbocharger.

12 Стр. 12 из 30 - Remove battery and battery holder. - Remove coolant hoses and Pull off/disconnect all electrical wires required from cylinder head and set aside. - Remove cable bracket - arrow - and lay wiring harness aside.

13 Стр. 13 из 30 - Remove coolant flange - arrows -. - Remove ribbed belt 13-1, Ribbed belt, removing and installing.. - Remove drift T10060A from ribbed belt tensioner. - Remove toothed belt 15-1, Toothed belt, removing and installing. - Remove cylinder head cover 15-1, Cylinder head cover, removing and installing. - Follow sequence for loosening cylinder head bolts. Note: Verify that all hose and line connections to engine, transmission and body have been disconnected. - Remove cylinder head. Cylinder head, installing Note: Pocket holes in engine block for cylinder head bolts must be free of oil and coolant.

14 Стр. 14 из 30 Do not remove new cylinder head gasket from package until immediately before installing. Handle new gasket extremely carefully. Damage will cause leaks. Replace cylinder head bolts. - Stuff clean cloths into cylinders so that no dirt or abrasive powder can get between cylinder wall and piston. - Do not allow dirt or abrasive powder to get into coolant either. - Carefully clean sealing surfaces of cylinder head and cylinder block. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100). - Thoroughly remove all sanding and grinding residue and remove cloths. - In the event the crankshaft has been rotated in the meantime: Set number 1 piston at TDC position and slightly turn crankshaft backward. - Position new cylinder head gasket. Text (replacement part number) must be visible. - Note centering pins in cylinder block - arrows-. - Install cylinder head. - Insert cylinder head bolts and tighten them hand-tight.

15 Стр. 15 из 30 - Tighten cylinder head bolts in tightening sequence shown as follows: Stage Tighten - Using torque wrench, tighten to 40 Nm. - Tighten an additional 90 ( 1 / 4 turn) using a rigid wrench. - Tighten an additional 90 ( 1 / 4 turn) using a rigid wrench. - Install cylinder head cover. Tightening sequence: 15-1, Tightening sequence cylinder head cover - Install toothed belt 15-1, Toothed belt, installing. Installation is in reverse order of removal. Fill with new coolant refilling. 19-1, Coolant, draining and Toothed belt, removing and installing

16 Стр. 16 из 30 Special tools, testers and auxiliary items required Engine support bridge A Feet A/13 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Locking Pin T10060A Note: In order to be able to remove the engine bracket, engine must be lifted quite far using engine support

17 Стр. 17 из 30 bridge A. To prevent damage to drive axles from significant bend angles, it is necessary to disengage drive axles from transmission. Toothed belt, removing 15-1, Toothed belt, removing. Toothed belt, installing 15-1, Toothed belt, installing Toothed belt, removing - Remove engine cover 24-1, Air filter/engine cover, removing and disassembling. For reasons of safety, remove Fuse 27 (on fuse panel C) - SC27- from fuse holder under instrument panel on left side before opening the fuel supply system, as the Fuel Pump (FP) will be activated by the drivers door contact switch. Warning! Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening hose connections, place rags around the connection point. Then release pressure by carefully pulling on hose.

18 Стр. 18 из 30 - Disconnect lines - 1, 2 and 3 -. To do so, press release buttons. - Disconnect connector Loosen coolant expansion tank and lay aside. - Remove ribbed belt and remove Locking Pin T10060A 13-1, Ribbed belt, removing and installing.. - Position engine support bridge A with feet A/13 and support engine in installation position. - Remove insulation pan

19 Стр. 19 из 30 Repair Manual, Body Exterior, Repair Group 50, front body; noise insulation. - Remove noise insulation at right. - Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

20 Стр. 20 из 30 - Remove harmonic balancer/belt pulley. - Remove bolts from lower section of toothed belt guard - arrows -. - Remove lower bolt Loosen bolts of right wheel housing liner and push it aside.

21 Стр. 21 из 30 - Remove bolt through hole in wheel housing. Note: The next repair steps are necessary in order to be able to lift the engine far enough. - Remove front pipe with catalytic converter. - Remove bolts and of pendulum support. - Disengage drive axles from transmission Repair Manual, Suspension, Wheels, Steering, Repair Group 40, Drive axle, servicing.

22 Стр. 22 из 30 - Remove A/C system lines from body - arrows-. Note: A/C system does not need to be opened! - Remove mounting bolts of subframe mount/engine bracket - arrows - and remove subframe mount completely. Caution! Make sure no components/hoses are damaged, overstretched or sheared off when engine is lifted using engine support bridge A.

23 Стр. 23 из 30 - Lift engine using engine support bridge A far enough until upper bolt of engine bracket can be loosened and removed. - Continue to raise engine until engine bracket can be removed upward. - Remove remaining bolts from toothed belt guard - arrows - and remove toothed belt guard from engine. - Mark rotational direction of toothed belt. - Loosen tensioning roller and remove toothed belt. - Turn crankshaft back slightly. Toothed belt, installing Note: When turning camshaft, crankshaft may not be at TDC for any cylinder. Valves and/or pistons may be damaged. Engine must not be hotter than lukewarm. - Set toothed belt on crankshaft gear (watch direction of rotation). - Secure lower section of toothed belt guard with two lower bolts. - Install harmonic balancer/belt pulley with new bolts. Tightening torque: 10 Nm plus an additional 90 turn.

24 Стр. 24 из 30 - Set crankshaft and camshaft to TDC cylinder 1 - arrows -. - Route toothed belt in sequence: Tensioning roller, camshaft gear, coolant pump and last over relay pulley - arrow -. Note:

25 Стр. 25 из 30 Be sure tensioning roller is properly seated in cylinder head. - Tension toothed belt. To do so, turn hex socket wrench on eccentric toward the right (direction of - arrow - ) until notch is above tab (toothed belt overstretched). - Release tension on toothed belt again. - Tension toothed belt until notch and tab align. - Tighten mounting nuts to 25 Nm. - Turn crankshaft two additional turns in direction of engine rotation until engine is at TDC again. For this, it is necessary that the last 45 ( 1 / 8 rotation) is turned without interruption. - Check tension of toothed belt again. Specified value: Tab and notch align.

26 Стр. 26 из 30 - Check valve timing again. If markings do not match: - Repeat valve timing adjustment. If markings match: - Install toothed belt cover - arrows -. - Install engine bracket on cylinder block from above and tighten bolts hand-tight. Note: Note different length of bolts. Bolt is approx. 25 mm shorter than bolts - 1 and Lower engine using engine support bridge A far enough until lower bolt can be tightened. - Tighten all bolts to 45 Nm. - Lower engine to installation position. - Install subframe mount for engine completely. Tightening torques 10-1, Subframe mount.

27 Стр. 27 из 30 - Bolt engine subframe mount to engine mount - arrows -, by bringing the contact surfaces into contact using engine support bridge A. Tightening torque: 60 Nm plus an additional 90 (1/4 turn). - Remove engine support bridge A. - Install ribbed belt 13-1, Ribbed belt, removing and installing.. - Connect fuel hoses to connections. Make sure connector couplings are securely fastened. - Install coolant expansion tank. - Install insulation pan Repair Manual, Body Exterior, Repair Group 50, Front body, noise insulation. - Re-insert Fuse 27 (on fuse panel C) -SC27- into fuse holder. - Install engine cover. Compression pressure, checking

28 Стр. 28 из 30 Special tools, testers and auxiliary items required Spark plug wrench 3122 B Puller T40039 Torque wrench V.A.G 1331 Compression tester V.A.G 1763

29 Стр. 29 из 30 Adapter V.A.G 1381/5A Test requirement: Engine oil temperature must be at least 30 C. Voltage supply OK - Remove engine cover. - Remove ignition coils with power output stage 28-1, Ignition coils with power output stage, removing and installing. - Remove spark plugs using spark plug removal tool 3122 B. - Check compression using compression tester V.A.G 1763 and adapter V.A.G 1381/5A. Note: Using tester operating instructions. - Have a second technician operate starter. - Activate starter until no further pressure increases are indicated by VAG 1381 or VAG 1763 compression tester. Compression values: Engine Code new bar positive pressure Wear limit bar positive pressure Difference between cylinders bar positive pressure BPY 11.0 to max Erase DTC memory of Engine Control Module (ECM) after completing work, as malfunctions were stored when

30 Стр. 30 из 30 disconnecting connectors Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided Functions".