Withdrawal
Observe precautions when disconnecting the battery. The battery is located in a hidden niche in the trunk. Switch off the ignition and remove the key from the ignition switch. Disconnect earth wire -arrow- from battery. Remove the hood. Drain coolant. Remove catalytic converter. Remove poly V-belt. Unscrew heat shield for left drive shaft -arrows-.
Vehicles with code letter AMF
Detach air hose -6- from turbocharger. Disconnect the hoses -5- from the charge pressure control system to the turbocharger and the charge pressure control air element. Disconnect ventilation hose -4-. Remove bolts -3- and remove air pipe from turbocharger.
Instruction. The air guide tube remains in the installation position and can be removed upwards later. Pos. -1- and -2- are ignored.
Vehicles with letter designation ATL, VNS
Detach vacuum hose -1- from boost pressure control vacuum unit and lay it aside. Remove bolts -2- and remove air pipe from turbocharger.
Instruction. The air guide tube remains in the installation position and can be removed upwards later.
Detach air hose -3- from turbocharger.
All cars
Unbolt bracket for air pipe from oil sump -arrows-. Detach right air hose -2- from intercooler. Pos. -1- ignore.
Unplug electrical connector at oil level and oil temperature sender -G266-. Unfasten electrical wiring. Depending on the version, the oil level and oil temperature sender -G266- can be located at the front on the oil sump.
If present, unfasten bracket -1-. Remove engine cover -arrows-. Remove the sound insulation underneath.
Pry off caps -3 and 4- on both parts of wiper arm with a screwdriver. Loosen the nuts on both parts of the wiper arm with a few turns. Loosen wiper blade levers -1 and 2- on axles one by one with light wiggles. Completely unscrew the nuts and remove both parts of the wiper arm. If it is not possible to remove the lever in this way, then in this case it is necessary to use a standard puller.
Disconnect washer fluid pipe -3-. If fitted, unplug electrical connectors -4 and 5- for heated windshield washer jets. Loosen hose clamp -6- using hose clamp pliers -VAG 1921- and remove drain hose from deflector grille. Remove rubber seal -1- from deflector grille. Remove air vent grille -2-.
Remove nuts and bolts -arrows-. Pull the fresh air duct forward and remove it by turning it towards the right side of the vehicle.
Vehicles with code letter AMF
Detach air hose -2- from mechanical exhaust gas recirculation valve. Detach vacuum hose -3- from mechanical exhaust gas recirculation valve. Detach vacuum hose -4- for air intake manifold flap vacuum unit.
Detach air hose -2- from intercooler. -Pos. 1- ignore.
Vehicles with code letter ATL
Detach air hose -3- from intake manifold flap motor -V157-, to do this unclip clamp -2- slightly. Detach vacuum hose -1- from mechanical EGR valve.
Detach air hose -2- from intercooler. Unplug electrical connector for charge pressure sender -G31- pos. -1-.
All cars
Attention! Risk of burns from contact with fuel lines or fuel heated to 100°C. Wait until the fuel has cooled down before opening the fuel line connections.
Mark and disconnect fuel pre-supply line -2- and fuel return line -1-. Unfasten the fuel lines.
Detach air hose -1- from air mass meter -G70-. Unplug electrical connector -3- for air mass meter -G70-. Loosen nut -2-. Remove hose -4- for crankcase breather from cylinder head cover. Pull out air pipe together with air mass meter -G70-.
If fitted, unplug electrical connector -arrow- for crankcase ventilation heater -N79-. Remove air pipe.
Vehicles with code letter ATL
Unplug electrical connector -arrow- for intake manifold flap motor -V157-. Unfasten electrical wiring.
All cars
Remove drain hose -2-. Remove water tank -1-.
Remove upper left coolant hose -pos. 1 and 2-.
Mark coolant supply hose -1- and coolant return hose -2- to heater heat exchanger and remove coolant hoses from bulkhead plate.
Vehicles with letter designation ATL, VNS
Detach vacuum hose -1-.
All cars
Detach vacuum hose -2- from tandem pump to brake servo.
Unfasten the vacuum hoses.
Unplug electrical connectors -2- for glow plugs. Pull out the release pin and unscrew the knurled nut -3- of the central connector of the unit injector module. Unplug connector for Hall sender -040-pos. -4-. Unplug electrical connector -7- for fuel temperature sender -G81-. Pos. -1, 5, b- ignore.
Detach oil pre-supply line -2- to turbocharger from oil filter bracket. Unscrew bracket for oil pre-feed line -3-. Pos. -1- ignore.
Unplug electrical connector -arrow- for coolant temperature gauge sender -G62-
Unbolt bracket for wiring harness from coolant connection -arrow-. Unfasten the wiring harness.
Detach upper coolant hose from expansion tank -upper arrow- and set aside.
Unscrew tensioner for poly V-belt -arrows-.
Remove top section of belt guard -arrows-.
Unscrew the vibration damper, to do this, hold the crankshaft at the central bolt with a spanner wrench.
Unbolt center and bottom section of belt guard -arrows-. Remove lower bolt -1- for engine mount. Bolts -2 and 3- are loosened later.
Vehicles with letter designation ATL, VNS
Remove bolts -1 and 2- and remove turbocharger support.
All cars
Remove oil return pipe -3- from cylinder block.
Loosen bolt -1- by approx. 3 turns. Loosen nut -2-. Unscrew oil return pipe -3- from turbocharger and lay it to one side.
Position crosshead -10.222 A- with adapters -10.222 A/13- and adapter -T40093/6- on the edges of the wing bolt connections.
Carefully! In this case, insert adapter -10. 222 A/13- in the bonnet catches -arrow-.
The bolt in the adapter -T40093/6- must be unscrewed with a clamp. Install adapter -T40093/6- so that its bracket points upwards. Hook the hook of the carabiner of the lead screw -10.222 A / 11 - pos. A - for the engine eye. Tighten the engine with the spindle -A- without lifting it. Additional right lead screw -pos. B is still free.
Vehicles with cover for engine mounting
Remove the cover of the engine mounting, to do this unscrew the bolts -1 and 2-.
Loosen bolts -1 and 3- and remove bracket with engine mounting -2-.
Vehicles without engine mount cover
The nut -3- may only be loosened to replace the engine mount.
Remove bolts -1 and 2- and remove bracket with engine mount.
All cars
Remove upper bolts -2 and 3- and remove engine support.
Carefully! It is allowed to scroll the engine only by the crankshaft in the direction of its rotation (clockwise). To rotate the engine shaft, install the center bolt on the crankshaft.
Set the crankshaft to the mark "TDC". The gap between both teeth of the camshaft sprocket must be opposite the marking "37." rear section of belt guard -arrows-. Secure camshaft bushing with tool -3359-. Secure crankshaft sprocket with crankshaft stop -T10050-.
Instruction. The crankshaft stop can only be pushed onto the sprocket teeth from the outside.
Markings for sprocket and crankshaft stop -T10050- must be opposite each other. The stud of the crankshaft stop -T10050- must engage in the seal bore. flange. Remove toothed belt: Toothed belt drive with hydraulically damped tensioning roller, toothed belt drive with friction damped tensioning roller. Remove bolts -1- and remove camshaft sprocket from bushing.
Loosen the bolt -1- of the bushing, using the wrench -T10051- to prevent the shaft from turning. Then loosen the bolt about 2 turns.
Loosen the bolt -1- of the bushing, using the wrench -T10051- to prevent the shaft from turning. Then loosen the bolt about 2 turns.
Remove toothed belt tensioner. Unscrew bolts -2...4-. Loosen dowel pin -1- using 2 M8 nuts locked one on top of the other.
Screw bracket -T10014- into threaded hole above coolant pump. Hook the hook of the carabiner of the free lead screw -10.222 A/11. pos. -B- at bracket -T10014-.
Raise the engine with the spindle -B- until the spindle -A- is unloaded. Remove spindle -A- and move to one side.
Loosen cylinder head cover bolts according to sequence -11...1-. -arrow, take into account.
Remove the bracket together with the fuel lines. Remove cylinder head cover.
Loosen cylinder head bolts according to sequence -1...8-. The second mechanic must carefully remove the cylinder head by lifting its top. Lay the cylinder head with the combustion chamber up on a soft bedding.
Installation
Instruction. Replace cylinder head bolts. Replace self-locking nuts and bolts. Replace bolts tightened to a certain angle, as well as cuffs and seals. When repairing, carefully remove sealant residues from the cylinder head and cylinder block. Avoid long scratches or gouges. Carefully remove the remnants of emery and grinding. There must be no oil or coolant in the blind holes of the cylinder head bolts. A new cylinder head gasket should be removed from the packaging immediately before installation. The gasket must be handled very carefully. Damage to the silicone layer and corrugated joints lead to loss of tightness. Cylinder heads with cracks between the valve seats can be operated without a decrease in service life if the crack width does not exceed 0.5 mm. Refinement of the diesel cylinder head is unacceptable. When installing a replaced cylinder head with the camshaft installed, the contact surfaces between the hydraulic tappets and the sliding surfaces of the cams must be lubricated with oil. The plastic pads included in the repair kit to protect open valves may be removed immediately before installing the cylinder head. Use clamps of the appropriate series to fasten all hose connections. After replacing the cylinder head or cylinder head gasket, the coolant and oil must be replaced. After working on the valve train, rotate the engine by hand at least 2 revolutions to make sure that no valve is in contact with the piston.
Check the location of the camshaft and crankshaft relative to the mark "TDC ': Camshaft lobes of cylinder 1 must point upwards symmetrically -arrows-.
The crankshaft sprocket must be secured with crankshaft stop -T10050-. Markings for sprocket and crankshaft stop -arrow- must be opposite each other. In this case, the pin of the crankshaft stopper must enter the seal hole. flange.
Pay attention to the marking of the cylinder head gasket.
1. Part number
2. Control code (disregard)
3. Holes
Instruction. If the cylinder head or cylinder head gasket is replaced, install a new gasket with an identical marking. In case of replacement of parts of the crank mechanism, it is necessary to re-determine the required thickness of the cylinder head gasket by measuring the amount of protrusion of the piston at TDC.
Install the cylinder head gasket. Observe the centering sleeves in the cylinder block. Pay attention to the installation position of the cylinder head gasket, mark "oben/top" or the part number must point to the block head. Install cylinder head. In the cylinder head, check the installation of all cylinder head bolt washers. Insert new head bolts and hand tighten.
Install the cylinder head bolts in 4 stages in the sequence shown as follows:
- 1. Tighten with a torque wrench to 40 Nm.
- 2. Tighten with a torque wrench to 60 Nm.
- 3. Turn with a spanner 90°.
- 4. Turn with a spanner 90°.
Instruction. Tightening the cylinder head bolts after repair work is not required.
Use thread varnish to tighten screws -2...4-. Tighten dowel pin -1- with 2 M8 nuts locked one on top of the other. Install the bushing on the camshaft. Tighten bolt -1-, using support wrench -T10051- to prevent rotation of shaft.
Install the camshaft sprocket on the bushing. The toothed sector -arrow- of the camshaft sprocket must be at the top.
Screw in bolts -1- not completely. Secure camshaft bushing with tool -3359-. Installation is in reverse order, while it is necessary to install the cylinder head cover. Install toothed belt (adjust valve timing): toothed belt drive with hydraulically damped idler pulley, toothed belt drive with friction damped idler pulley.
Instruction. Follow the instructions for removing and installing the toothed belt. The hoses and the hose fitting of the charge air system must be free of oil and grease before installation. Never use lubricants.
Install vibration damper. Install poly V-belt. Install the engine mount with bracket. Install catalytic converter. Install the air ducts in the clamps. Electrical connectors and their laying. Observe precautions after connecting the battery. Install the wiper arm. Change oil. Replace coolant.
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