Remove the engine cover. To do this, remove the two plugs, unscrew the two nuts and remove the casing. On engines 115/130 hp the casing is screwed with three nuts.
Remove the toothed belt.
Disconnect the wires from the switches and glow plugs.
Clean the piping connections to the fuel injectors and high pressure fuel pump. Unscrew the connecting nuts and remove the fuel lines. Close the holes with suitable plugs.
Remove the glow plugs and fuel injectors from the cylinder head.
Paint mark the position of the crankshaft pulley, for which put a mark on the pulley and opposite the mark on the cylinder block. Then turn the crankshaft 90° (clockwise or counterclockwise), so that none of the pistons are at TDC. Before installing the toothed belt, the crankshaft must be again set to the TDC position of the piston of the first cylinder.
To unscrew the bolts of the cylinder head, you must use the appropriate socket wrench (e.g. HAZET 990 Sig-12). In the reverse sequence shown in Figure 2.42, unscrew the cylinder head mounting bolts.
The cylinder head of a diesel engine must not be machined.
For correct installation of the cylinder head and cylinder head gasket, screw guide bolts AUDI-3070/9 or HAZET 2570-09 into the extreme hole of the cylinder block intended for the cylinder head bolts. In the absence of guide bolts, they can be made independently, for which it is necessary to use two old cylinder head bolts. Cut off the head bolts and cut a slot for a screwdriver instead. After installing the cylinder head, using a screwdriver, unscrew the guide bolts (see fig. 2.40).
If new pistons are installed on the engine, the protrusion of the pistons from the cylinder block must be measured and a new cylinder head gasket must be used.
Depending on the amount of protrusion of the pistons, it is necessary to select the thickness of the new cylinder head gasket. The gasket has a marking made in the form of embossed numbers and notches (see fig. 2.41).
Install the cylinder head, being careful not to damage the exhaust manifold heat shield.
Insert and hand tighten eight new cylinder head bolts with washers.
Unscrew the two guide bolts with a screwdriver and screw in two new cylinder head bolts in their place.
Gradually, in the sequence shown in Fig. 2.42 tighten bolts of fastening of a head of the block of cylinders in several stages.
The tightening torques of the cylinder head bolts are the same as for 1.8-I engines (125/150 hp).
The tightening torques for the cylinder head bolts of the 1.9-I-TDI engine are as follows:
1st stage - tighten with a torque of 40 Nm;
2nd stage - tighten with a torque of 60 Nm;
3rd stage - tighten by an angle of 90°;
Step 4 - Tighten 90°.
Check the injection timing of the fuel pump.
Diesel engines 115/130 hpUnscrew the timing belt pulley from the hub and hold the hub on the camshaft. To do this, use the AUDI T10051 and T10052 fixtures.
Unscrew the toothed belt tensioner. Unscrew the stud using two nuts.
Unscrew nuts of fastening of a cover of a head of the block of cylinders in sequence return shown in drawing 2.43.
Tighten the nuts for fastening the cylinder head cover in the sequence from 1 to 13 (pic. 2.43). Tightening torque 10 Nm.
Before installing the cylinder head cover gasket, lubricate the transitions (even on the opposite side) from bearing caps to cylinder head with VW/AUDI-AMV174 004 01.
Tighten the cylinder head bolts in the same sequence as on the 1.8-I gasoline engine.
Pic. 2.39. Diesel cylinder head 1.9-I-TDI (110 HP)
1 - cylinder head cover,
2 - oil filler cap,
If the cap is leaking, replace the gasket.
3 - sealing gasket,
If the gasket is damaged, it must be replaced.
4 - disc washer,
5 - nut, 10 Nm,
6 - cap,
7 - to the intake manifold,
8 - collar,
9 - pressure control valve,
10 - sealing sleeve,
If damaged, a new sealing sleeve must be used.
11 - cylinder head cover gasket,
12 - crankcase ventilation hose,
13 - a bolt of fastening of a head of the block of cylinders,
When installing, use new bolts.
The bolt torques are the same as for the 1.8-I engine (125/150 HP).
14 - clamp,
A new clamp must be used when installing.
15 - sealing ring,
When installing, a new O-ring must be used.
16 - conical sealing ring,
17 - pipelines for supplying fuel under high pressure to fuel injectors,
Pipelines must be replaced as a set.
Do not bend piping.
Tighten the connecting nuts of the pipelines with a torque of 25 Nm.
18 - cylinder head,
The head cannot be resurfaced.
19 - cylinder head gasket,
20 - bolt, 20 Nm,
21 - eye for lifting the engine
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