Removing Cylinder Head

REMOVING AND INSTALLING CAMSHAFTS AND CYLINDER HEAD

Removing:

1. Align lifting-platform pads beneath jacking points and raise car.

2. Place protective covers on fenders.

3. Disconnect ground lead from battery.

4. Disconnect breather hose for toothed-belt cover from rear of lower section of air filter. Detach entire filter assembly and remove.





5. Remove air-flow sensor and disconnect support (M 8 bolt) from intake manifold.





6. Remove throttle-valve actuating cable complete with reversing roller and holder. Remove oil dipstick. Slacken hose clamps at intake manifold, brake booster and breather hose and remove.





7. Remove cover of fuel-distribution pipe. Slacken hose clamp for fuel return line and disconnect hose. Disconnect fuel feed while countering.





8. Disconnect vacuum hose, fuel-i me-pressure damper and fuel-distribution pipe from intake manifold1 disconnect plug from idle actuator, remove fuel rail with injection valves and place to one side.





9. Disconnect throttle-valve switch connector. Unbolt intake manifold from cylinder head and remove.

10. Remove engine underguard. Open coolant drain plug and catch coolant in suitable container.

11. Detach exhaust at exhaust-manifold flange.





12. Pull off spark-plug caps and remove distributor cap. Slacken hose clamp at ATF reservoir.

13. Unbolt and remove upper and lower toothed-belt covers, front camshaft sprocket bracket and cylinder-head cover.

Camshaft Timing Mark:

Crankshaft TDC Mark:

14. Turn engine in direction of rotation until cylinder 1 ignition TDC is reached.









15. Relieve tension of camshaft toothed belt by slackening nut A and bolt B, pressing toothed-belt tensioner against the pressure of the spring with Special Tool 9200 and removing toothed belt from camshaft sprocket.





16. Remove distributor rotor. Insert 3 temporary retaining bolts M 5 x 20 to hold camshaft sprocket to avoid upsetting basic camshaft setting when camshaft central bolt is slackened.

17. Slacken central bolt while countering. Remove camshaft sprocket.

18. Remove rear bracket.

19. Unbolt and remove chain tensioner.

Note: Chain-tensioner plunger is spring loaded. When removing, compress plunger and after removal hold in this position with a piece of wire or a retaining clamp.

20. Remove bearing cover from cylinders 1 + 3

Hold both camshafts in the bearings with Special Tool 9226. Undo and remove front double bearing bridge and bearing cover.





Note: The rear double bearing bridge may remain on the cylinder head.

21. Undo Special Tool evenly, remove both camshafts with chain and lay together on one side.

22. Undo cylinder head. Undo in sequence: from outside to inside.

23. Remove cylinder head.

Note: If oil has been mixed with water, the cylinder head must be subjected to a thorough visual inspection (hairline fractures). At the same time, check the cooling system for leaks. Use test unit VW 1274 above the expansion tank for the leak test (max. 1 bar). The camshaft cover must be removed for visual inspection.