cylinder head cover 1. Fuel rail, with fuel injection pipes, do not change the curved shape of the fuel injection pipes; 2. Bolt, 22 Nm; 3. Injection unit (piezo injector); 4. Bolt; 5. Latches; 6. Cylinder head cover; 7. Bolt, 10 Nm; 8. Fuel lines; 9. Gasket, replacement if damaged or leaking; 10. Bolt; 11. Cover; 12. Bushing, fuel mounts. ramps, replace if damaged
Removing the cylinder head cover
- 1. Loosen the nuts in the sequence -7...1-.
Sequence of tightening the cylinder head cover bolts
- 2. Tighten the bolts by hand in several stages in the sequence -1...7-.
- 3. Tighten the bolts in sequence -1... 7- with a torque wrench to a torque of 10 N'M. Make sure that there are no distortions in the position of the cylinder head cover.
Take off
Remove engine cover -arrows-. Remove the noise insulation pad for the injectors. Remove the injectors. Remove fuel ramp. Release the brackets -arrows- and remove the toothed belt protective cover. Remove bracket -1- with wiring for lambda probe and temperature sensor in front of diesel particulate filter from cylinder head cover. Move and release the engine crankcase ventilation -3-
Unscrew the fuel bolts. highways -arrows-.
Unscrew bolts -1-...-7- and remove cylinder head cover.
Install
Install in reverse order. Observe the following: Replace the bolt seal if damaged. Install the cylinder head cover, tightening sequence
Cylinder head.
Note: The plastic pads included in the repair kit to protect open valves may only be removed immediately before installing the cylinder head. When replacing the cylinder head, the coolant should also be changed.
cylinder head 1. Cylinder head, after replacing, drain the old one and pour new coolant into the cooling system; 2. Washer for the cylinder head bolt; 3. Cylinder head bolt; before installation, install washers in the cylinder head; 4. Bolt, 25 Nm; 5. Eyelet for hanging; 6. Gasket, replace; 7. Vacuum pump; 8. Bolt, 10 Nm; 9. Coolant connection fitting; 10. Bolt, 10 Nm; 11. Gasket, replace; 12. Bolt, 25 Nm; 13. Eyelet for hanging; 14. Cylinder head gasket, replace, after replacement, drain the old one and pour new coolant into the cooling system; 15. Hall sensor -G40-, for camshaft position; for removal and installation, it is necessary to remove the toothed belt from the camshaft gears and unscrew the diverter roller; 16. Bolt, 10 Nm
Disconnecting the cylinder head
Unscrew the cylinder head bolts in sequence
Tightening sequence for cylinder head bolts
- 1. Tighten with a torque wrench to 40 Nm.
- 2. Tighten with a torque wrench to 60 Nm.
- 3. Tighten 90°using a regular wrench.
- 4. Tighten 90°using a regular wrench.
Tightening the cylinder head mounting bolts after repair work is not necessary.
Cylinder head seal markings 1. Part number; 2. Holes; 3. Not taken into account
If different values are obtained for the piston projections, the largest size should be used for shim selection. Thickness of the installed seal. The cylinder head depends on the protrusion of the pistons. When replacing, install a gasket with identical markings -arrow 2-.
Removing the cylinder head
Disconnect the battery. Remove the stretch. Drain the coolant. Remove the air housing. filter. Remove the exhaust gas recirculation radiator. Remove the exhaust pipe. Remove the turbocharger. Remove the timing belt. Remove the valve cover. Release hose clamps -arrows- and remove air duct hose.
Unscrew bolt-1-.
When working on the injection system, follow the rules for maintaining cleanliness. Disconnect the fuel supply -1- and return -2- lines.
Remove coolant hoses -3- and -4-.
Remove hose clamps -1 - and -2- and disconnect coolant hose.
Unscrew the nut -3- of the exhaust gas recirculation system pipe. Unscrew bolts -4- and -5- and move exhaust gas recirculation pipe to the side. The EGR pipe does not need to be removed.
Unscrew the bolt -arrow- on the cylinder head of the oil pressure line leading to the turbocharger.
Unscrew bolt -4-, unblock air hoses of exhaust gas pressure sensor 1.
Remove the vacuum connection -1- from the end wall of the plenum chamber; to do this, disconnect the vacuum hose -2- at the rear -arrow-.
Disconnect the following plug connectors.
- 3. Intake manifold servomotor with variable geometry -V183-
- 4. Intake manifold flap motor -V157-
- 5. Exhaust gas recirculation valve -N18-
Unscrew bolts -1- and remove camshaft timing belt gear.
Unscrew the camshaft hub bolt -1- and hold it with the counter support -T10051-. Unscrew the bolt approximately 2 turns.
Place the puller -T10052- on the camshaft hub and screw the bolts -1 - into the hub. To remove the camshaft hub, screw in the bolt -2- and hold it by the hexagon (at 30) puller Remove the hub from the camshaft cone.
Remove bolt -1- from belt guard.
Unscrew the Hall sensor bolt -arrow- and place the Hall sensor -G40- to one side.
Unscrew the cylinder head bolts in the sequence -1...10-. A second mechanic is required to remove the cylinder head. Remove the timing belt tension roller when removing the cylinder head from the locating pin. Lift the cylinder head first from the gearbox side and remove it from the timing belt cover. Make sure that the toothed belt tension roller does not fall out.
Install
Install in reverse order. Please note the following: Risk of damage to the seal. surfaces. Carefully remove any remaining sealant from the cylinder head and cylinder block. Do not allow long scratches or burrs to form. Risk of damage to the cylinder block. There should be no oil or coolant in the blind holes of the cylinder head mounting bolts. Danger of cylinder head gasket leakage. During repairs, carefully remove any remaining sealant from the cylinder head and cylinder block. Do not allow long scratches or burrs to form. Carefully remove residues after sanding and sanding. A new cylinder head gasket should be removed from its packaging immediately before installation. To prevent damage to the silicone layer and the grooves of the cylinder head gasket, the gasket must be handled with extreme care. Risk of damage to open valves. When installing an exchange cylinder head, the plastic base should be removed to protect the open valves only when it is in direct contact with the cylinder head. Risk of damage to valves and piston crowns after working on the valve mechanism. To ensure that no valve comes into contact with the cylinder head during operation, carefully turn the crankshaft at least 2 turns. Bolts that are tightened at a tightening angle should be replaced. Replace self-locking nuts, lip seals, gaskets and seals. rings. Modifications to the cylinder head of TDI engines are prohibited. If a cylinder head from an exchange stock is installed, the contact surfaces between the rocker arm and the camshaft bearing housing should be lubricated. Hose fittings, air pipes and hoses must be cleaned of oil and grease before installation. To ensure reliable fastening of the air hoses to the fittings, the threaded connections of already used clamps should be treated with a rust remover. After replacing the cylinder head or cylinder head gasket, the coolant and oil must be completely replaced. Before installing the cylinder head, remove the crankshaft lock -T10050- and turn the crankshaft against the direction of rotation of the engine shaft until all pistons are evenly below TDC. To center, screw guide bolt -3070- into the outer holes on the suction side. Place the cylinder head gasket with the marking facing up.
Pay attention to the cylinder head gasket markings: If different values were obtained for the piston projections, then the largest size should be used to select the gasket. The thickness of the cylinder head seal to be installed depends on the protrusion of the pistons. When replacing, install a gasket with identical markings -arrow 2-. When installing the cylinder head, the tension roller must be installed on the stud. Place the cylinder head, insert the remaining 8 cylinder head screws and tighten by hand. Using a screwdriver, unscrew the guide bolt from 3070 through the screw holes and install the cylinder head screws. Then tighten the cylinder head bolts in 4 stages. Attach the rear toothed belt guard to the cylinder head. Install the camshaft hub and gear. Secure the camshaft and high-pressure pump using the locking pin for unit injector -3359-. Rotate the crankshaft in the direction of engine rotation to TDC and secure with the crankshaft clamp -T10050-. Install the timing belt. Install in reverse order. Please note the following: Install the cylinder head cover. Install the poly V-belt. Fill with coolant.
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