Withdrawal
1. Remove the motor and place it on a suitable support or mounting stand (see relevant chapter).
2. Disconnect the plug 1 from the throttle valve, and also remove the clamp 2 and disconnect the crankcase ventilation hose (see illustration).
3.2. Disconnect the plug 1 from the throttle valve, and also remove the clamp 2 and disconnect the crankcase ventilation hose
3. Disconnect plugs 1, 2, 5 and 6 from the intake manifold bracket, then disconnect plugs 3 and 4 (see illustration).
3.3. Disconnect plugs 1, 2, 5 and 6 from the intake manifold bracket, then disconnect plugs 3 and 4
4. Disconnect the low pressure hose (see arrow in illustration).
Z.4. Disconnect the low pressure hose (see arrow)
5. Disconnect the fuel injector plugs on rails 6 and 7, the wires of which are combined into harnesses 1 and 5 (see illustration).
3.5. Disconnect the fuel injector plugs on rails 6 and 7, the wires of which are combined into harnesses 1 and 5
6. Disconnect the low pressure hose 4 from the fuel pressure regulator (see illustration 3.5).
7. Unscrew the fastening bolts 2 and 3 and remove the ramps 6 and 7 together with the fuel injectors (see illustration 3.5).
8. Unscrew the mounting bolts (see arrows in illustration) and remove the rear left engine lifting eye.
3.8. Unscrew the fastening bolts (see arrows) and remove the rear left eye to lift the engine
9. Unscrew the mounting bolts (see arrows in illustration) and remove the intake manifold.
3.9. Unscrew the fastening bolts (see arrows) and remove the intake manifold
Attention! The intake ports of the cylinder head must be covered with a clean cloth.
10. Unscrew the cap (see arrow in illustration) oil filter and remove the replacement filter element from the filter housing.
3.10. Unscrew the cap (see arrow) oil filter
11. Drain the engine oil from the oil filter using a special pumping tool, the catalog number of which is VAG1358 or VAG1782. Wrap a rag around the oil filter housing to catch any escaping engine oil.
12. Remove the bolts (see arrows in illustration) fasteners and remove the oil filter.
3.12. Unscrew the bolts (see arrows) fasteners and remove the oil filter
13. Disconnect the plug 1 from the motor mount, unscrew the nut 2 and remove the mount (see illustration).
3.13. Disconnect the plug 1 from the engine support, unscrew the nut 2 and remove the engine support
14. Unscrew the bolts 1 and 2 of the power steering return line holders, remove the clamp (see arrow in illustration) and remove the pipeline.
3.14. Unscrew the bolts 1 and 2 of the power steering return line holders, remove the clamp (see arrow) and remove the pipeline
15. Remove the bolt (see arrow in illustration) probe guide tube holder and remove the tube by pushing it upwards.
3.15. unscrew the bolt (see arrow) probe guide tube holder and remove the tube by pushing it up
16. Unscrew bolts 1 and 2, remove fastening clamps (see arrows in illustrations 3.16 and 3.16a) and disconnect the coolant lines.
3.16. Unscrew bolts 1 and 2, remove fastening clamps (see arrows) and disconnect the coolant circulation pipe. Left cylinder head
3.16a. Unscrew bolts 1 and 2, remove fastening clamps (see arrows) and disconnect the coolant circulation pipe.Right cylinder head
17. Disconnect the plug 2 of the coolant temperature sensor, then unscrew the nut 1 and disconnect the wiring harness (see illustration).
3.17. Disconnect the plug 2 of the coolant temperature sensor, then unscrew the nut 1 and disconnect the wiring harness
18. Unscrew bolts 2-5 holders of the pipeline of a cooling liquid and remove the pipeline (see illustration).
3.18. Unscrew the bolts 2-5 of the coolant pipe holders and remove the pipe
19. Unscrew the bolts 1-4 fastening the fresh air intake valves to the exhaust valves (see illustration).
3.19. Unscrew the bolts 1-4 fastening the fresh air intake valves to the exhaust valves
20. Disconnect plugs 1-4 lambda probes (oxygen sensors) and release the wires from the holders (see illustrations 3.20 and 3.20a).
3.20. Disconnect plugs 1-4 and release the wires from the holders. Left cylinder head | 3.20a. Disconnect plugs 1-4 lambda probes (oxygen sensors) and release the wires from the holders. Right cylinder head |
21. Right cylinder head. unscrew the bolt (see arrow in illustration) fixing the lining of the intake pipe.
3.21. unscrew the bolt (see arrow) fixing the lining of the intake pipe. Right cylinder head
22. Unscrew the nuts 1-3 fastening the intake pipe to the exhaust manifold and disconnect the pipe (see illustrations 3.22 and 3.22a).
3.22. Unscrew the nuts 1-3 securing the intake pipe to the exhaust manifold and disconnect the pipe. Left cylinder head | 3.22a. Unscrew nuts 1-3 fastening the intake pipe to the exhaust manifold and disconnect the pipe. Right cylinder head |
23. Unscrew the nuts 1-12 fastening and remove the exhaust manifold (see illustrations 3.23 and 3.23a).
3.23. Unscrew nuts 1-12 of fastening and remove a final collector. Left cylinder head | 3.23a. Unscrew nuts 1-12 of fastening and remove a final collector. Right cylinder head |
24. Remove the bolts (see arrows in illustrations 3.24 and 3.24a) and remove the heat shields.
3.24. Unscrew the bolts (see arrows) and remove the heat shield. Left cylinder head | 3.24a. Unscrew the bolts (see arrows) and remove the heat shield. Right cylinder head |
25. Disconnect the plugs 1-4 from the ignition coils, unscrew the bolts 5 and 6 and move the coil wiring harness away from the place of work (see illustrations 3.25 and 3.25a). Then carefully remove the ignition coils (see arrows in illustrations 3.25 and 3.25a).
3.25. Disconnect the plugs 1-4 from the ignition coils, unscrew the bolts 5 and 6 and move the wiring harness of the coils away from the place of work | 3.25a. Disconnect the plugs 1-4 from the ignition coils, unscrew the bolts 5 and 6 and move the coil wiring harness away from the place of work. Then carefully remove the ignition coils (see arrows). Right cylinder head |
26. Remove the clamp (see arrow in illustrations 3.26 and 3.26a) fasteners and disconnect the crankcase ventilation hose.
3.26. Remove clamp (see arrow) fasteners and disconnect the crankcase ventilation hose. Left cylinder head | 3.26a. Remove clamp (see arrow) fasteners and disconnect the crankcase ventilation hose. Right cylinder head |
27. Unscrew bolts of fastening of a cover of a head of the block of cylinders in descending sequence of their numbering - 15-1 - and remove a cover of a head of the block of cylinders (see illustrations 3.26 and 3.26a).
28. Disconnect the plug (see arrow in illustrations 3.28 and 3.28a) from the camshaft position sensor (hall sensor).
3.28. Disconnect the plug (see arrow) from the camshaft position sensor (hall sensor). Left cylinder head | 3.28a. Disconnect the plug (see arrow) camshaft position sensor (hall sensor). Right cylinder head |
29. Unscrew the nut (see arrow in illustration) and disconnect the wire «masses» (-) away from the right cylinder head, move the wiring harness away from the work area.
3.29. Unscrew the nut (see arrow) and disconnect the wire «masses» (-) from right cylinder head
30. Unscrew the bolts 1-6 and remove the left side of the protective cover of the timing drive (see illustration).
3.30. Unscrew bolts 1-6 and remove the left part of the protective cover of the timing drive
31. Unscrew the bolts 1-6 and remove the right side of the protective cover of the timing drive (see illustration).
3.31. Unscrew bolts 1-6 and remove the right side of the protective cover of the timing drive
32. Turn the crankshaft in the direction of rotation of the engine, using a special overlay T40049, which is attached to the flange on the crankshaft with two bolts (see illustration 3.32). The crankshaft must be rotated so that the splines on the rear ends of the camshafts are horizontal (see arrows in illustration 3.32a).
3.32 Rotate the crankshaft in the direction of engine rotation | 3.32a. Turn the crankshaft in the direction of engine rotation so that the splines on the rear ends of the camshafts are horizontal (see arrows) |
33. Lock the camshafts with a special stop bar, the catalog number of which is T40046 (see illustration). If you cannot easily install the bar, then turn the crankshaft one more turn (360°).
3.33. Lock the camshafts with a special stop bar, the catalog number of which is T40046
Attention! The thrust bar must not be used as a stopper when tightening the bolts for fastening the shaft sprockets.
Attention! Since after locking the camshafts, the crankshaft must be locked, which may have to be turned to install the thrust pin, the camshafts can be fixed later.
34. Unscrew the plug from the bottom of the cylinder block and screw in the thrust pin 3242 instead to lock the crankshaft (see illustration). If necessary, turn the crankshaft slightly to the right or left so that the stop fits into the corresponding hole on the crankshaft web. The tightening torque of the thrust pin is 20 Nm.
3.34. Unscrew the plug from the bottom of the cylinder block and screw in thrust pin 3242 instead to lock the crankshaft
Attention! Stop 3242 must not be used as a stop when tightening bolts.
35. Lock the camshafts with a stop bar T40046 (see illustration 3.33), unless they were previously blocked.
36. Press on the left / right cylinder head intake camshaft drive chain (see arrow in illustrations 3.36 and 3.36a), to press the plunger of the chain tensioner, and in this position, fix the tensioner with a drill 1 with a diameter of 3.3 mm, inserting it into the hole on the tensioner housing.
3.36. Press on the intake camshaft drive chain of the left cylinder head (see arrow), to press the plunger of the chain tensioner, and in this position, fix the tensioner with a drill 1 with a diameter of 3.3 mm, inserting it into the hole on the tensioner housing | 3.36a. Press on the intake camshaft drive chain of the right cylinder head (see arrow), to press the plunger of the chain tensioner, and in this position, fix the tensioner with a drill 1 with a diameter of 3.3 mm, inserting it into the hole on the tensioner housing |
37. Unscrew the bolts 1 and 2 fastening the sprocket to the intake camshaft and the camshaft position adjuster and remove the sprocket and adjuster (see illustrations 3.37 and 3.37a).
3.37. Unscrew bolts 1 and 2 fastening the sprocket to the intake camshaft and the camshaft position adjuster and remove the sprocket, governor and drive chain. Left cylinder head | 3.37a. Unscrew bolts 1 and 2 securing the sprocket to the intake camshaft and the camshaft position adjuster and remove the sprocket, governor and drive chain. Right cylinder head |
Installation
Installation of chains of a drive of camshafts is made in sequence, return to removal.
Attention! The intake camshaft position sensor gear, which is located on the shaft position adjuster, must be in the correct position after the chain is installed.
38. Put the intake camshaft drive chain on the sprocket and regulator, install them together with the chain in their places and screw in the sprocket and regulator fastening bolts by hand.
39. Perform a preliminary tightening of the bolt securing the sprocket to the intake camshaft with a force of 40 Nm.
40. Install special tool T40047 on the regulator and the gear of the camshaft position sensor, and its other end on the head of bolt 1 securing the sprocket to the intake camshaft (see illustrations 3.40 and 3.40a).
3.40. Install special tool T40047 on the regulator and the gear of the camshaft position sensor, and its other end on the head of bolt 1 of the sprocket to the intake camshaft. Left cylinder head: 3409 - a wedge that presses the plunger of the chain tensioner | 3.40a. Install special tool T40047 on the regulator and the gear of the camshaft position sensor, and its other end on the head of bolt 1 of the sprocket to the intake camshaft. Right cylinder head: 3409 - a wedge that presses the plunger of the chain tensioner |
41. Pre-tighten the bolt 2 fastening the camshaft position adjuster with a force of 40 Nm (see illustrations 3.40 and 3.40a).
42. Remove tool T40047 and perform the final tightening of the bolt securing the sprocket to the intake camshaft in several passes: 1st pass - tighten the bolt with a force of 100 Nm; 2nd pass - tighten the bolt 90°.
43. Reinstall tool T40047 and tighten the camshaft position adjuster bolt in several passes: 1st pass - tighten the bolt to 100 Nm; 2nd pass - tighten the bolt 90°.
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