Left cylinder head: Remove the high-pressure pump timing belt and the timing belt tensioning roller. Unscrew the bolt -1 - of the toothed belt drive pulley approximately 2 turns, using counter support -3036- for this purpose.
Remove the toothed belt drive pulley using a puller -T10320-.
Unscrew bolts -arrows- and leave rear toothed belt cover in installation position.
Unscrew the oil dipstick guide tube bolt -2-. -Pos. 1- do not take into account.
Unscrew union nuts -2- and -3-, loosen and remove high pressure line. -Pos. 1,4- and -arrows- are ignored.
Remove the tee from the coolant hose -arrow-.
Disconnect plug connector -1 - intake manifold flap motor 2 -V275- -item. 4-. -Pos. 2,3- and -arrow- are ignored.
Loosen clamp -arrow- and exhaust gas recirculation pipe -1.
Right cylinder head: Remove the right intermediate pipe. Remove the coolant pipe from the top right. Unscrew the bolts -arrows- and remove the high pressure line protection shield. Unscrew union nuts -1- and -4-, loosen and remove high pressure line. -Pos. 2.3 - do not take into account. Unscrew bolts -1- and -2- for engine mounting and exhaust gas recirculation radiator pump -V400-. Release wiring harness using lever -80 - 200- -arrow-.
Disconnect coolant line -arrow-. Disconnect the plug connectors for the glow plugs for cylinders 2 and 3.
Disconnect electrical connector -1- of intake manifold flap motor -V157-. -Arrows- ignore.
Disconnect plug connector -1 - (black) exhaust temperature sensor 1-G235-. Remove plug connector -2- from bracket (orange) exhaust gas recirculation temperature sensor -G98- from the bracket and disconnect the connector.
Place a rag under the disconnection point to collect any leaking fuel. Disconnect fuel supply -1- and return -2- lines. Unscrew bolts -arrows- and set aside. ramp with connected fuel hoses. -Pos. 1, 2-ignore.
All
Loosen the cylinder head bolts in the sequence -1...8-. Unscrew the bolts and carefully remove the cylinder head. Risk of damage to the glow plug rods when installing the cylinder head. A removed cylinder head with installed glow plugs must not be placed on the contact surface, since the glow plug rods slightly protrude beyond the contact surface.
Installation
Install in reverse order. 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. The new cylinder head seal 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 it from covered valves only when it comes into 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 engine at least 2 turns. Replace bolts that were overtightened. Replace self-locking nuts, lip seals, gaskets and seals. rings. Modifications to the cylinder head of TDI engines are prohibited. When installing an exchange cylinder head with installed camshafts, the contact surfaces between the hydraulic compensators, rocker arms and the working surfaces of the cams should be lubricated with oil. Hose fittings, air pipes and hoses must be cleaned of oil and grease before installation. Secure all hose connections with hose clamps of the appropriate series. 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. If the cylinder head or cylinder head gasket has been replaced, the coolant and oil must be replaced. Before installing the cylinder head, install the crankshaft and camshafts in "TDC": The fixing bolt -3242- must be screwed into position "TDC" crankshaft -1-.
The camshafts on both cylinder heads must be secured using the adjustment font -T40060-. The pin -arrow- in the locating pin -T40060- must be parallel to the axis of symmetry of the camshaft chain drive.
Observe the markings on the cylinder head gasket
- 1. Holes
- 2. Part number
Note: After replacing the cylinder head gasket or cylinder head, select a new cylinder head gasket according to the number of holes in the old gasket. If parts of the crank mechanism have been replaced, then a new cylinder head gasket should be selected according to measurements of the protrusion of the pistons in the position "TDC. It is impossible to confuse the left and right cylinder head gaskets; they have different shapes.
Clean the sealing surfaces from oil and grease. Consider the expiration date of the sealant. Cut off the tube spout at the front mark (hole diameter approx. 5 mm). The bolted connection of the parts must be closed 15 minutes after applying the sealant.
Left cylinder head: Apply beads of sealant -1- and -2- to the clean seating surface of the cylinder block and lower timing chain cover as shown in the illustration.
The sealant is applied in the specified quantity.
a = 7mm, b = 7mm, c = 7mm.
Apply cylinder head gasket. Apply beads of sealant -1- and -2- to the cylinder head seal as shown in the illustration.
Right cylinder head: Apply beads of sealant -1- and -2- to the clean seating surface of the cylinder block and lower timing chain cover as shown in the illustration.
The sealant is applied in the specified quantity.
a = 7mm, b = 7mm, c = 7mm.
Install the cylinder head seal. Apply a bead of sealant -1- and -2- into the recesses of the cylinder head gasket.
All
Pay attention to the centering sleeves -arrows- in the cylinder block. Mounting position of the cylinder head seal: marked "top" or the spare part number for the cylinder head. Install the cylinder head.
Tighten the cylinder head bolts. Do not tighten the cylinder head bolts.
Left cylinder head: Install the exhaust gas recirculation system pipe. Install the oil dipstick guide tube. Remove the toothed belt tensioning roller and the high-pressure pump toothed belt.
Right cylinder head: Install the coolant pipe on the top right. Install the right intermediate pipe.
All
Install high pressure fuel lines. Install the cylinder head cover. Install the upper part of the intake manifold. Install the camshaft drive chains. Change the oil. Replace coolant. Check the fuel. systems for tightness.
Compression check
Oil temperature is about 80°C. Battery voltage is at least 12.5 V. Remove engine cover -arrows-. Disconnect the plug connectors for all glow plugs. Disconnect el. Connector for fuel pressure regulator valve -N276- -pos. 1- for fuel ramp of cylinder bank 1 (right). To relieve pressure in the fuel. ramp and turn on the engine for a short time.
Remove all glow plugs.
Screw in the adapter -VAG 1763/8- in place of the glow plugs and connect the compressor gauge -VAG 1763-.
The second mechanic must crank the engine crankshaft with the starter until the pressure on the compression gauge stops increasing. Check each cylinder.
Compression values | Overpressure bar |
New | 28...33 |
Wear limit | 21 |
Maximum difference between cylinders |
Installation
Installation is in reverse order, observing the following. Install glow plugs. Since the engine was started with the connectors disconnected, an error was stored in the engine control unit: "Interrogate fault memory" in function "Vehicle self-diagnosis".
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