Cylinder Head, Removing and Installing
Cylinder head, removing and installing
Special tools and equipment
Part 1 Of 2:
Part 2 Of 2:
^ 10-222A Engine support bridge
^ 10-222 A/8 Adaptor
^ 3035 Injector line wrench
^ 3070 Guide pins & handle-1112 mm
^ T 10014 Engine support
^ VAG1306 Drip tray for VAG1202A
^ VAG1331 Torque wrench: 5 to 50 Nm (3 7 to 37 ft. lbs.)
^ VAG1332 Torque wrench: 40 to 200 Nm (30 to 148 ft. lbs.)
^ VAG1921 Hose clip pliers
Requirements
^ Engine must NOT be more than warm to the touch.
^ Pistons must NOT be positioned at TDC.
Removing
CAUTION: Obtain radio anti-theft code from customer before disconnecting battery ground strap.
- With ignition switched OFF, disconnect battery Ground strap.
- Remove engine cover.
- Remove Air Cleaner.
- Remove connecting pipe between Charge Air cooler and intake manifold/EGR Vacuum Regulator Solenoid valve.
- Remove sound dampening tray:
- Drain engine coolant.
- Disconnect fuel supply and return lines at fuel filter.
WARNING: Fire hazard! Do NOT have anything in the area that can ignite Diesel fuel!
- Seal lines so fuel system is not contaminated by dirt etc.
- Remove front exhaust pipe.
- Remove ribbed belt.
- Unscrew wiper arms.
^ M8 hex nuts = 20 Nm (15 ft. lbs.)
- Remove plenum chamber cover.
- Disconnect fuel supply and return lines at fuel filter.
- Remove fuel filter with bracket
- Disconnect all coolant, vacuum and breather hoses from engine.
- Disconnect all wiring connections from transmission, Generator and starter and move to one side.
- Loosely unscrew coolant reservoir and place to side.
- Remove toothed belt guard - upper section.
- Remove valve cover.
- Remove brake booster vacuum pump.
- Unscrew turbocharger oil return line to cylinder block.
- Unscrew oil supply line at turbocharger
- Remove injection lines.
Note: Always remove injection lines as a set. Use 3035 offset tubing wrench to loosen/tighten the injection lines.
- Remove return line from injector jets/injection pump.
- Remove glow plug harness connector.
- Install engine support bracket 1 0-222A with 1 0-222A/1 legs.
- Loosely unscrew subassembly (engine side) from upper engine bracket (arrows).
- Remove engine mount and engine bracket.
- Lift engine again slightly using spindle -B-.
Note: Both lifting eyes are located on the cylinder head, therefore an additional bracket must be attached to the block to support the engine.
- Attach T 10014 bracket to cylinder block using threaded hole in water pump area (as illustrated).
- Lift engine slightly using second spindle -A- until spindle -B- is relieved.
- Remove spindle -B-.
- Position engine at TDC with camshaft sprocket loosened and toothed belt removed from camshaft sprocket.
- Remove tension roller and camshaft sprocket.
- Unscrew upper bolt of belt guard, rear.
- Loosen socket head bolts in sequence given, then remove bolts completely.
- Carefully lift off cylinder head.
Installing
Note:
^ Always replace cylinder head bolts.
^ Make sure that there isn't any oil or coolant in the cylinder head bolt hollows (in the cylinder head).
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ When repairing, carefully remove any gasket remains from the cylinder head and cylinder block. Ensure that no long grooves or scratches are created. When using abrasive paper do not use a grade coarser than 100 (e.g. 80).
^ Carefully remove any emery or abrasive remains.
^ Handle the new gasket with extreme care. Damaging will lead to leaks.
- Turn crankshaft to TDC mark before installing cylinder head.
- Turn crankshaft against engine direction of rotation until all pistons are approximately equally spaced below TDC.
- To centralize: screw guide pins from 3070/9 into outer threaded holes on intake side.
- Install new cylinder head gasket.
^ Lettering (Part No.) must be readable.
- Install cylinder head, screw in 8 remaining head bolts and tighten by hand.
- Remove guide pins with removal tool from 3070 by turning removal tool counter-clockwise until pins are free
- Install remaining cylinder head bolts and tighten hand-tight.
- Tighten cylinder head in following four stage sequence:
1. Tighten initially using torque wrench:
Stage I = 40 Nm (30 ft. lbs.)
Stage II = 60 Nm (44 ft. lbs.)
2. Turn further with a normal wrench:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Assembly is basically a reverse of the disassembly sequence.
^ Installing toothed belt and timing adjustment, Refer to Timing Belt, Service and Repair
^ Coolant, filling.