Withdrawal
Observe precautions when disconnecting battery terminals. The battery is located in a special compartment in the trunk. Switch off the ignition and remove the key from the ignition lock. Disconnect cable "masses" -arrow- from the battery. Remove the engine hood.
Attention! When opening the lid, hot steam or hot coolant may come out of the expansion bank, wrap the lid with a rag and carefully open the tank.
Open cap -arrow- of expansion tank.
Remove noise insulation -arrows-.
Place a pallet for service cranes -VAS 6208- under the engine. Detach lower coolant hose from radiator -arrow- and drain off coolant.
Instruction. The split piece between pre- and main catalytic converter must not be bent more than 10°. Risk of damage!
Support detachable element with locking tool -T40035-.
Remove bolts -2- on pre-catalyst bracket.
Instruction. Pos. -1- ignore. Mark the direction of rotation of the V-ribbed belt with chalk or felt-tip pen. Reversing the running direction of a used belt can damage it.
To loosen the tension of the V-ribbed belt, use a spanner wrench to tilt the tensioner -in the direction of the arrow-. Lock tensioner by inserting locking pin -T10060 A- or -T10060- into locking holes. Remove poly V-belt.
Remove engine cover -arrows-. Remove the noise shield located below, to do this, disconnect the crankcase breather hose.
Using a screwdriver, remove caps -3- and -4- from wiper arms. Loosen the nuts on both levers a few turns. Release levers -1- and -2- by slightly deflecting them on the wiper shafts. Loosen nuts completely and remove wiper arms.
Disconnect the washer fluid pipe -3-. Unplug electrical connectors -4- and -5- for heated washer nozzles. Release hose clamp -b- Using hose clamp pliers -VAG 1921-c, remove drain hose from fairing grille. Remove rubber seal -1- for fairing grille. Remove fairing grille -2-.
Remove bolts and nuts -arrows-. Remove the fresh air intake duct and hang it over the right side of the vehicle.
Unscrew nuts -arrows- for precatalyst/turbocharger.
Disconnect the pre-catalyst from the turbocharger. Tie the pre-catalyst to the body.
Unplug electrical connector -2- from air mass meter -G70-. Detach vacuum hose -1-. Release hose clamp -4- and remove air duct with air mass meter -G70-. Loosen nut -3-.
Remove air hose -2- connecting intercooler and intake manifold. Pos. -1- ignore.
Attention! The temperature of fuel lines or fuel in vehicles equipped with an engine with unit injectors can reach 100°C. Allow the fuel to cool before disconnecting the fuel lines, otherwise severe burns may result.
Mark and disconnect fuel pressure line -2- and fuel return line -1-.
Mark the position of the supply hose -1- and the drain hose -2- in relation to the heat exchanger for the heater and remove the hoses from the front wall of the body.
Remove bolts -arrows- and remove air duct from turbocharger.
Detach air hose -1- from turbocharger. Unscrew oil pressure line -2- from turbocharger. Pos. -3- ignore.
Detach vacuum hose -2- from vacuum charge pressure regulator and move it clear. Unscrew oil return line -3- from cylinder block. Unbolt support -1- for turbocharger from cylinder block.
Detach vacuum hose -1- from brake booster. Unplug electrical connector -2- for fuel temperature sender -G81- and move wiring clear. Unplug electrical connector -3- for coolant temperature indicator sender -02-/ coolant temperature sender -662-.
Detach vacuum hose -1- from mechanical EGR valve. Detach vacuum hose -2- from throttle valve control valve -N211-.
Unplug electrical connectors -2- for glow plugs. Pull out the pin and loosen the knurled nut -3- on the central connector of the unit injectors. Unplug electrical connector -4- for Hall sender -G40- and remove connector from bracket. Pos. -1, 5, 6 - ignore.
Detach upper coolant hose from expansion tank -upper arrow-
Detach upper left coolant hose at location marked -1- from coolant connection. Pos. -2- ignore.
Unbolt bracket -arrow- for upper wiring harness from coolant pipe. Unscrew bracket -2- for oil pressure line from turbocharger below coolant pipe.
Unscrew poly V-belt tensioner -arrow-.
Remove upper toothed belt cover by opening retaining clips -arrows-.
Loosen the damper while holding the center bolt with a spanner wrench.
Unscrew center and bottom toothed belt covers -arrows-.
Remove bolt -1- for engine support. Bolts -2- and -3- will be removed later.
Bolt front right load eye -T40016- to cylinder head.
Screw rear left load eye -T40016/1- to cylinder head.
Position crosshead -10-222 A- with adapters -10-222 A/13- and 2 spindles -A- and -8- on wing connecting edges. The lead screws of the traverse are facing forward. The additional right spindle -B- is not yet engaged.
Install 2 eyelets -10-222 A/12- on rear left load eye -T40016- on cylinder head. Attach the suspension tool -2024 A- to the engine and to the spindle -A- of the traverse -10-222 A- as shown in the figure.
Instruction. To equalize the position of the center of gravity of the power unit, the hook bars must be inserted as shown in the figure. The hooks and locking pins of the hanging device must be secured with cotter pins.
Tighten the motor on the lead screw without lifting the motor. Loosen nut -3- when replacing engine mounting. Remove bolts -1- and -2- and remove bracket with engine hitch.
Remove bolts -2- and -3- and remove engine support.
Carefully! The engine may only be turned by the crankshaft in the direction of engine rotation (clockwise). To rotate the engine shaft, install the center bolt on the crankshaft.
Bring the crankshaft to the TDC position of the first cylinder. The arrow on the toothed belt rear cover must point to the toothed rim of the hub -arrows-. Secure camshaft hub with locking pin -3359-. Secure crankshaft gear with crankshaft stop -T10050-.
Instruction. The stopper should be installed on the toothed belt gear only from the front side of the toothed rim.
Markings on toothed belt sprocket and crankshaft stop -T10050- must be opposite each other. The pin of the crankshaft stop -T10050- must engage in the seal hole. flange.
Mark the direction of rotation of the toothed belt with chalk or felt-tip pen. Remove bolts -arrows- for camshaft gear.
Insert the Allen key into the hexagon hole as far as it will go and turn the tensioning roller counterclockwise -arrow- until the tensioner is locked with the locking plate -T10008-.
Instruction. To avoid damage, insert the Allen key as far as it will go. The tensioning element of the toothed belt is equipped with an oil stop, so it can only be squeezed gradually and with a uniform force.
Unscrew the fixing nut of the tension roller.
Remove bolts -arrows- and remove toothed belt tensioner. Remove toothed belt. Remove locking pin -3359-.
Remove bolts -arrows- and remove camshaft sprocket from hub.
Loosen the bolt -1- of the hub, holding it with support -T10051-. Loosen the bolt about 2 turns.
Attach puller -T10052- to hub and screw in bolts -1-. Remove the hub from the camshaft, holding the hexagon of the puller with a 30 wrench and screwing in the bolt -2-. Remove the hub from the camshaft cone.
Remove toothed belt tensioner. Release screws -2... 4-. Remove stud -1- with two lock nuts M8.
Screw bracket -T10014- into threaded hole above coolant pump.
Fasten the spindle -B-traverse -10-222 A- to the bracket -T10014- Tighten the motor on the spindle -B- until the spindle -A- is unloaded. Attach lifting device -2024 A- to engine. Set aside the lifting device -2024 A- and the spindle -A-. Unscrew bolts -arrows- for fuel line bracket on cylinder head cover. Release cylinder head cover bolts in sequence -11...1-. Remove the bracket together with the fuel lines. Remove cylinder head cover.
Release cylinder head bolts in sequence -1... 8-. Carefully remove the MCC. Place the MCC on a soft pad with the side of the combustion chambers facing up.
Installation
Instruction. Replace cylinder head bolts. When installing, replace self-locking nuts and bolts. Replace bolts tightened to a certain angle, as well as cuffs and gaskets. 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 grease in the blind holes for 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 continue to be used without reducing the shelf life, if these are small cracks with a width of max. 0.5 mm. Additional processing of the cylinder head is prohibited. When installing a cylinder head from an exchange fund with a camshaft installed, the adjacent surfaces between the hydraulic tappets and the cam bed must be lubricated with engine oil after installing the head. 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. Replace contaminated oil. When replacing the cylinder head or cylinder head gasket, drain the old one and fill in new coolant. After working on the valve train, rotate the engine at least 2 revolutions by hand to ensure that no valve is in contact with the piston.
Check whether the camshaft and crankshaft are at TDC: the cams of the first cylinder must point upwards -arrows-.
The crankshaft gear must be locked using the crankshaft stop -T10050-. Markings on toothed belt sprocket and crankshaft stop -arrow- must be opposite each other. In this case, the pin of the stopper must enter the hole in the seal. flange.
Follow the markings on the cylinder head gasket.
- 1. Part number
- 2. Control code (ignore)
- 3. Holes
Instruction. When replacing the cylinder head gasket or the cylinder head itself, use a gasket with the same marking. After replacing the parts of the crank mechanism, it is necessary to re-determine the parameters of the new cylinder head gasket according to the protrusion of the pistons at TDC.
Install the cylinder head gasket. Make sure that the centering bushings are in the cylinder block. Observe the installation position of the cylinder head gasket, mark "oben" or part number must face the head of the block. Install cylinder head. Make sure that all cylinder head washers for the cylinder head bolts are present in the cylinder head. Insert new cylinder head bolts and tighten. Tighten the cylinder head bolts in 4 steps in the sequence shown: 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°. It is not necessary to tighten the cylinder head bolts after repair work.
Lubricate bolts -2...4- with thread varnish and tighten. Tighten stud -1- with two lock nuts M8.
Push the hub onto the camshaft. Tighten bolt -1-, holding it with support -T10051-.
Install the camshaft gear onto the hub. The toothed segment -arrow- of the camshaft gear must be at the top.
Do not fully screw in the bolts. Secure camshaft hub with locking pin -3359-. Further installation is carried out in the reverse order, install the cylinder head cover. Install toothed belt (adjust valve timing). Follow all instructions for removing and installing the toothed belt. The hoses and pipes of the air pressurization system must be cleaned of oils and grease before installation. Never use lubricants. Install vibration damper Install poly V-belt. Install the engine mount bracket. Install pre-catalyst with main catalytic converter. Observe precautions when disconnecting battery terminals. Install and adjust wiper arms. Check oil level. Replace coolant.
Tightening torques:
- Hall sender -G40- to cylinder head: 10 Nm 1)
- Rear toothed belt cover to cylinder head M6: 10 Nm 1), М8 20 1)
- Stud to cylinder head: 15 Nm
- Hub to camshaft: 100 Nm
- Engine support to cylinder block: 45 Nm
- Pressure oil line to oil filter holder: 22 Nm
- Oil return line to turbocharger: 15 Nm
- Upper coolant pipe to suspension eye: 20 Nm
- Turbocharger holder to turbocharger: 20 Nm
- Turbocharger holder to cylinder block: 20 Nm
- Oil return line to cylinder block: 30 Nm
- Bracket for wiring harness to coolant pipe: 10 Nm
- Bracket for oil pressure line to coolant pipe: 10 Nm
- Guide tube for oil dipstick to oil filter holder: 10 Nm
- Oil dipstick guide tube to hanging eye: 10 Nm
- Air duct to turbocharger: 8 Nm
1) Lubricate bolts with thread varnish before installation.
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