Removal and Installion

Special tools and equipment
^ 3035 Tubing wrench
^ Counter holder
^ 3070 Handle and guide pins 3070/9
^ T40001 Two-arm puller
^ V.A.G 1306 Drip pan
^ V.A.G 1331 torque wrench (5 to 50 Nm) or equivalent





^ V.A.G 1332 Torque wrench (40 to 200 Nm) or equivalent.

Requirements
^ Engine must NOT be more than warm to the touch.
^ Pistons must NOT be positioned at TDC.

Removing

CAUTION: Obtain the radio anti-theft code from the customer before disconnecting file battery ground strap.

- With ignition switched OFF, disconnect battery ground strap.

Note: All cable clamps and straps that were removed or cut during removal must be replaced and installed in same position.

- Remove engine cover.
- Remove air cleaner.
- Drain engine coolant.
- Remove refrigerant hoses at cylinder head with spring clamp pliers V.A.G 1921
- Remove ribbed belt
- Remove front exhaust pipe with Three Way Catalytic Converter

WARNING: Fire hazard! Do NOT have anything in the area that can ignite Diesel fuel!





- Disconnect fuel pressure and return lines at fuel injection pump (arrows).
- Disconnect vacuum and ventilation lines from cylinder head.
- Disconnect glow plug connectors from glow plugs.
- Remove all electrical wires from cylinder head and lay aside.
- Remove oil pressure line and oil return line for turbocharger and cylinder head.
- Remove fuel injector lines.

Note: Always remove two-part injector line assembly as one unit. To disconnect use wrench 3035.

- Remove vacuum pump for brake booster.
- Remove toothed belt cover upper part.
- Remove valve cover.
- Remove toothed belt from camshaft sprocket.
- Slightly turn crankshaft counterclockwise of engine rotation.





- Loosen center bolt on camshaft sprocket 1 turn. Counterhold using tool 3036.

Note: Do not use alignment tool 3418 as counterhold. Always use tool 3086.





- Install two-arm puller T40001 with claw -A- and claw -B- at center of camshaft sprocket. Counter-hold puller using wrench -C-.
- Remove camshaft sprocket and tensioner.
- Remove bolts for belt cover at rear of cylinder head.





- Loosen and remove cylinder head bolts according to sequence shown.
- Carefully lift off cylinder head, guiding bolt for tensioner through rear of belt cover.

Installing

Note:
^ Always replace cylinder head bolts.
^ Ensure that there is no oil or coolant in the cylinder head bolt holes of the cylinder block.
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damaging it will lead to leaks.

- Place clean rags into cylinder bores to block out dirt.

Note: Do not allow any contaminants to enter engine coolant.

- Carefully remove any gasket remains from cylinder head and cylinder block. Ensure that no long grooves or scratches are created.

Note: When using abrasive paper, do not use a grade coarser then 100.

- 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: thread guide pins from 3070/9 into outer threaded holes on injection pump side.
- Install new cylinder head gasket. Lettering (Part No.) must be readable.
- Install cylinder head, thread 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°)
Continue assembly in reverse order of disassembly.

- Install toothed belt and adjust timing.
- Fill with coolant.
- Check DTC memory.
- Read readiness code.
If the DTC memory was erased or the engine control module is subject to low voltage with ignition ON, reset readiness code again.