4cylinder direct petrol injection engine 1.8L 2.0L_Audi TT_Type_8J_MK2_Dong co xang

Tài liệu hướng dẫn sửa chữa đại tu động cơ xăng trên xe 4cylinder direct petrol injection engine 1.8L 2.0L_Audi TT_Type_8J_MK2_Dong co xang. Cung cấp các thông tin cần thiết cho Kỹ thuật viên thực hiện sửa chữa nhanh chóng, hiệu quả, chính xác

Procedure before opening high-pressure section of injection system

Working on vehicles with start/stop system

Using testers and measuring instruments during a road test

Working on the exhaust system

3.1 Working on the fuel system

When working on the fuel system note the following warnings:

The fuel system operates at extremely high pressure This can cause injury.

♦ The fuel pressure in the high-pressure section of the in‐ jection system must be reduced to a residual pressure prior to opening the system.

♦ Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure to dissipate.

– Procedure before opening high-pressure section of injection system ⇒ Rep gr 24

Observe the following to prevent injuries to persons and damage to the injection and ignition system:

♦ Always switch off the ignition before connecting or discon‐ necting electrical wiring for the injection or ignition system or tester cables.

♦ Always switch off ignition before washing engine.

♦ Faults are stored in engine control units if electrical connectors were unplugged and engine was started: „Generate readiness code“ in „Guided Functions“ ⇒ Vehicle diagnostic tester

To prevent irreparable damage to the electronic components when disconnecting the battery:

♦ Observe notes on procedure for disconnecting the battery.

♦ Always switch off the ignition before disconnecting the battery.

3.2 Procedure before opening high-pres‐ sure section of injection system

♦ The injection system consists of a high-pressure section

(maximum approx 120 bar) and a low-pressure section

♦ The fuel pressure in the high-pressure section must be reduced to a residual pressure of approx 6 bar prior to opening the system Procedure ⇒ Rep gr 24

3.3 Working on the cooling system

When working on the cooling system note the following warnings:

Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is hot.

♦ To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully.

Overheating can occur if the filler cap is not fitted properly.

♦ The filler cap must engage positively and audibly when it is closed.

3.4 Working on vehicles with start/stop sys‐ tem

When performing repairs on vehicles with start/stop system, note the following:

Risk of injury due to automatic engine start on vehicles with start/stop system.

♦ On vehicles with activated start/stop system (this is indi‐ cated by a message in the instrument cluster display), the engine may start automatically on demand.

♦ Therefore it is important to ensure that the start/stop sys‐ tem is deactivated when performing repairs (switch off ignition, if required switch on ignition again).

3.5 Using testers and measuring instru‐ ments during a road test

Note the following if testers and measuring instruments have to be used during a road test:

Accidents can be caused if the driver is distracted by test equipment while road-testing, or if test equipment is not prop‐ erly secured.

Persons sitting in the front passenger's seat could be injured if the airbag is triggered in an accident.

• The use of test equipment while driving causes distraction.

• There is an increased risk of injury if test equipment is not secured.

♦ Move the passenger's seat back as far as it will go.

♦ Use only vehicle diagnosis and service information sys‐ tem -VAS 5052 A- or diagnosis system -VAS 5053-

♦ The test equipment -1- must rest flat on the passenger's thighs (as shown in illustration) and must be operated by the passenger.

3.6 Working on the exhaust system

When working on the exhaust system please note the following:

Avoid damage to flexible joint.

♦ Do not bend flexible joint more than 10°.

♦ Install flexible joint so that it is not under tension.

♦ Take care not to damage wire mesh on flexible joint.

Rules for cleanliness when working on fuel supply system, injection system and

injection system and turbocharger“, page 6

Routing and attachment of pipes, hoses and wiring

Installing radiators, condensers and charge air coolers

4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger

Even small amounts of dirt can cause malfunctions For this rea‐ son, please observe the following rules when working on the fuel supply system, injection system and turbocharger:

♦ Carefully clean connection points and the surrounding area with engine cleaner or brake cleaner and dry thoroughly before opening.

♦ Seal off open pipes/lines and connections immediately with clean plugs, e.g from engine bung set -VAS 6122-

♦ Place parts that have been removed on a clean surface and cover them over Use only lint-free cloths.

♦ Carefully cover or seal open components if repairs cannot be carried out immediately.

When installing components, ensure they are clean and unpack replacement parts only immediately before use Avoid using parts that have been stored outside their original packaging, such as in toolboxes, to maintain optimal performance and reliability.

♦ When the system is open, do not work with compressed air and do not move the vehicle.

♦ Protect unplugged electrical connectors against dirt and mois‐ ture and make sure connections are dry when attaching.

4.2 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.

– Check complete fuel system for leaks.

– If leaks are found although the connections have been tight‐ ened to the correct torque, the relevant component must be renewed.

– Road-test vehicle and accelerate with full throttle at least once.

– Then inspect high-pressure section of fuel system again for leaks.

♦ When working on the engine, all open inlet and exhaust ports must be sealed with suitable plugs (e.g from engine bung set

-VAS 6122- ) to prevent foreign particles from entering the en‐ gine.

Contact corrosion can occur if unsuitable fasteners are used (e.g. bolts, nuts, washers, etc.).

For this reason, only fasteners with a special surface coating are used.

Additionally, all rubber and plastic parts and all adhesives are made of non-conductive materials.

Always install new parts if you are not sure whether used parts can be re-fitted ⇒ Electronic parts catalogue

♦ We recommend using only genuine replacement parts; these have been tested and are compatible with aluminium.

♦ We recommend the use of Audi accessories.

♦ Damage caused by contact corrosion is not covered under warranty.

4.5 Routing and attachment of pipes, hoses and wiring

Before removing any components, mark all fuel lines, hydraulic lines, vacuum lines, activated charcoal filter system lines, and electrical wiring to ensure they can be re-installed in their original positions and connected correctly Consider making sketches or taking photographs for reference if needed.

♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐ cient clearance from all moving or hot components in engine compartment (little space in engine compartment).

Special tools and workshop equipment required

– Check all vacuum lines in the complete vacuum system for:

– Check vacuum line to solenoid valve and from solenoid valve

– If a fault is stored in the memory, check the vacuum lines lead‐ ing to the corresponding component and also check the re‐ maining vacuum lines in the system.

If you are unable to maintain pressure with the hand vacuum pump (VAS 6213) or notice an immediate drop in pressure, it is essential to inspect the hand vacuum pump and the connecting hoses for any leaks.

4.7 Installing radiators, condensers and charge air coolers

Even with proper installation of the radiator, condenser, and charge air cooler, minor impressions on the fins may occur These slight distortions do not indicate damage to the components, and if the fins are only minimally affected, replacing the radiator, condenser, or charge air cooler is unnecessary.

♦ Drip tray for workshop hoist

♦ Lambda probe open ring spanner set -3337-

♦ Tool set for wiper arms -T10369-

♦ The engine is removed from underneath together with the gearbox.

♦ Fit cable ties in the original positions when installing.

♦ Collect drained coolant in a clean container for re-use or dis‐ posal.

♦ All open inlet and exhaust ports must be sealed with suitable plugs (e.g from engine bung set -VAS 6122-

The fuel system operates at extremely high pressure This can cause injury.

♦ Do not open the high-pressure section of the injection system when removing the engine.

When removing the engine for repairs that require accessing the high-pressure section, it is essential to carefully reduce the fuel pressure in this area to a safe residual level before opening it.

– Reduce fuel pressure in high-pressure section of injection sys‐ tem ⇒ Rep gr 24

To prevent irreparable damage to the electronic components when disconnecting the battery:

♦ Observe notes on procedure for disconnecting the battery.

– Take out luggage compartment floor covering.

– Remove rear cross panel trim if cover for negative battery ter‐ minal is located behind rear cross panel trim ⇒ Rep gr 70

– Release retaining clips -arrows- and detach cover for negative terminal.

– Loosen nut a few turns and disconnect battery clamp on earth wire -arrow- from battery terminal.

– Open filler cap on coolant expansion tank.

– Unscrew bolts -arrows- and remove air duct.

– Unplug electrical connector -1- from air mass meter -G70-

– Unscrew bolt -4- and remove air cleaner housing.

– Remove bolts -arrows- and detach bracket for air cleaner housing.

– Remove noise insulation ⇒ Rep gr 66

– Remove noise insulation on left and right sides -arrows-.

– Remove noise insulation frame ⇒ Rep gr 50

– Remove air pipe -item 1 and 2-.

– Unplug electrical connector -2- for radiator outlet coolant tem‐ perature sender -G83-

Collect drained coolant in a clean container for re-use or disposal.

– Place drip tray for workshop hoist -VAS 6208- beneath engine.

– Pull off retaining clip, remove coolant hose -1- and drain off coolant.

– Disconnect coolant hose from continued coolant circulation pump -V51- -arrow- and drain off remaining coolant.

Disregard items marked -2, 3, 4 and arrow-.

– Remove bolts -1- and lift off radiator cowl.

– Unplug electrical connector -arrow- and move electrical wire clear.

– Unscrew bolt -4- and detach air hose.

– Detach coolant hose at top of radiator -arrow-.

– Remove bolts -arrows- on reverse side of radiator.

If a used belt runs in the opposite direction when it is refitted, this can cause breakage.

♦ Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen for re-installation.

– To slacken poly V-belt turn tensioner in direction of -arrow-.

– Remove poly V-belt and release tensioner.

Risk of injury caused by fuel.

♦ To allow the fuel pressure to dissipate, wrap a clean cloth around the connection and carefully loosen the connec‐ tion before opening the fuel system.

Observe rules for cleanliness when working on the fuel supply system ⇒ page 6

– Detach fuel hose -1- and move clear.

– Release activated charcoal filter -arrow B-, lift off -arrow A- and move clear to one side.

– Disconnect coolant hoses -arrows- and move clear.

For illustration purposes, the installation position is shown with the engine removed.

– Remove bolt -arrow- for air pipe.

– Loosen hose clip -1- and remove air pipe.

– Press release tabs and disconnect air hose -2-.

Pay attention to earth wire -arrow- when installing.

– Detach coolant hoses going to heat exchanger -arrows-.

– Remove nuts (accessible from above) -arrows- securing front exhaust pipe to turbocharger.

– Detach vacuum hose from brake servo -arrow-.

– Pry off caps on windscreen wiper arms with a screwdriver.

– Loosen nuts -arrows- several turns.

– Apply puller -T10369/1- to wiper arm -1-, as shown in illustra‐ tion.

– Apply thrust piece -2- onto wiper shaft.

– Turn bolt -3- in clockwise direction until wiper arm is pulled off wiper shaft.

– Remove nuts and detach windscreen wiper arms.

Risk of damage to plenum chamber cover.

To remove the plenum chamber cover, apply a small amount of soap solution where the windscreen meets the cover Begin at the edge of the windscreen and gently lift the plenum chamber cover off the retainer.

– Detach plenum chamber cover -2- by pulling it carefully off re‐ tainer at windscreen.

– Move clear engine wiring harness at rear of plenum chamber partition panel.

– Remove engine control unit ⇒ Rep gr 24

– Unplug electrical connector -1- for engine wiring harness

– Release wiring protector -1- for engine wiring harness

– Slide the two clips in the direction of the -arrows- and remove cover from electronics box in engine compartment.

– Open wiring duct brackets -arrows-.

– Unclip electrical connector -1- from bracket and unplug.

– Open wiring duct bracket located underneath.

– Unclip wiring harness for engine control unit from wiring duct.

– Place engine wiring harness with engine control unit on top of engine.

– Secure engine control unit to prevent it falling.

– Unclip electrical connector -2- from bracket and unplug.

– Unscrew terminal 30 wire -arrow- from electronics box in en‐ gine compartment and move it clear.

Use removal lever -80 - 200- to lever out the wiring clips.

– Detach cable support bracket from gearbox -arrows-.

– Pull pipe/hose assembly -A- off bracket -B-.

– Detach securing clip -arrow 1- from gearbox selector lever

-A- and pull off gear selector cable.

– Detach securing clip -arrow 2- from gate relay lever -B- and pull off gate selector cable.

– Detach securing clip -arrow 1- and pull off gear selector cable.

– Press detent -arrow 2- down onto stop and remove relay lever together with cable end-piece (move relay lever in normal di‐ rection of operation).

– Tie selector cables with cable support bracket to one side.

– Detach clutch slave cylinder -arrows B-, place to one side and secure with wire Do not disconnect pipes.

Do not operate clutch pedal with slave cylinder removed.

– Remove heat shield for drive shaft (right-side) -arrows-.

– Unbolt drive shafts (left and right) from gearbox flange shafts.

– Cut open cable tie -arrow- for protective cover -3-.

– Push back protective cover and unscrew B+ cable at starter solenoid switch

– Remove nut -1- for earth wire.

Dual clutch gearbox 02E (four-wheel drive)

Risk of damage to control unit (mechatronic unit) by static dis‐ charge.

♦ Do NOT touch connector contacts in gearbox connector with your hands.

– Touch vehicle earth with bare hands to eliminate any static charge.

– Turn retainer catch anti-clockwise and unplug electrical con‐ nector -4- at gearbox.

Items -1, 2- and -arrow- can be disregarded.

– Move wiring harnesses -arrows- clear and disengage electri‐ cal connector -1- at bracket.

– Unbolt heat shield for drive shaft (right-side) from bevel box

– Unbolt drive shaft (left-side) from gearbox flange.

– Unbolt drive shaft (right-side) from bevel box flange.

– Tie up drive shafts with cable ties.

Take care not to damage the surface coating of the drive shafts.

– If fitted, remove nut -1- (left-side).

– Unscrew nuts -arrows- (left-side) for swivel joint ⇒ Rep gr

– Detach swivel joint from wishbone.

– Swing suspension strut (left-side) outwards and support with support bracket -2024 A /1- as shown in illustration.

Accident risk from loose components of support bracket.

♦ Secure retaining pin and wishbone with locking pin

– Remove bolts -1- for cable support bracket.

– Pull off securing clip -3- -arrow- and remove selector lever ca‐ ble from gearbox.

Dual clutch gearbox 02E (front-wheel drive)

– Press securing clip -A- up and detach.

– Press selector lever cable off gearbox selector lever -arrow- and pull selector lever cable out of support bracket -D-.

♦ Take care not to bend or kink selector lever cable.

– Cut open cable tie -arrow- for protective cover.

– Push back protective cover -1- and unscrew B+ cable at starter solenoid switch.

Risk of damage to control unit (mechatronic unit) by static dis‐ charge.

♦ Do NOT touch connector contacts in gearbox connector with your hands.

– Touch vehicle earth with bare hands to eliminate any static charge.

– Turn retainer catch anti-clockwise and unplug electrical con‐ nector -4- at gearbox.

– Remove heat shield for drive shaft (right-side) -arrows-.

– Unbolt drive shafts (left and right) from gearbox flange shafts

– Tie up drive shafts with cable ties.

Take care not to damage the surface coating of the drive shafts.

– If fitted, remove nut -1- (left-side).

– Unscrew nuts -arrows- (left-side) for swivel joint ⇒ Rep gr

– Detach swivel joint from wishbone.

– Swing suspension strut (left-side) outwards and support with support bracket -2024 A /1- as shown in illustration.

♦ Secure retaining pin and wishbone with locking pin

– Mark position of flexible coupling and flange for bevel box in relation to each other for re-installation.

– Remove bolts -arrows- for flexible coupling for propshaft at bevel box (counterhold using a suitable lever at the triangular flange).

Make sure not to damage the oil seal -arrow- in the propshaft flange.

♦ Push the propshaft horizontally to the rear and towards the right side of vehicle as far as possible.

– Unscrew bolts -1- and -2- at bracket for electrical connector for Lambda probe (on underbody) and remove cover.

– Remove bolt -3- and move electrical wire to Lambda probe clear.

– Take plug-in connector -arrow- out of bracket.

– Unplug electrical connector for Lambda probe after catalytic converter -G130- and move clear.

– Unscrew remaining nuts (accessible from below) securing front exhaust pipe to turbocharger -arrows-.

– Remove bolts -arrows- and detach bracket for exhaust system and cross piece.

Avoid damage to flexible joints.

♦ Do not bend flexible joints in front exhaust pipe more than

– Slacken nuts -arrows- at clamp and disconnect exhaust sys‐ tem.

– Detach front exhaust pipe with catalytic converter and front silencer.

– Remove bolts -1, 2, 3- and remove pendulum support.

– Unplug electrical connector -1- at oil level and oil temperature sender -G266-

– Unclip bracket -2- for wire to oil level and oil temperature sender -G266- from subframe.

– Loosen bolts -arrows- of assembly mounting at engine approx.

– Loosen bolts -arrows- of assembly mounting at gearbox ap‐ prox 2 turns.

Vehicles with dual clutch gearbox 02E:

– Loosen bolts -arrows- of assembly mounting at gearbox ap‐ prox 2 turns.

– Unplug electrical connector -1- for magnetic clutch on air con‐ ditioner compressor.

Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.

– Remove bolts -arrows- for air conditioner compressor.

Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

– Tie up air conditioner compressor together with refrigerant ho‐ ses to longitudinal member (refrigerant hoses remain connec‐ ted).

– Attach engine bracket -T10359- with bolt -1- to cylinder block

Tapped hole for bolt -1- secures continued coolant circulation pump -V51-

– Insert engine and gearbox jack -V.A.G 1383 A- in engine bracket -T10359-

– Raise engine/gearbox assembly slightly.

To unscrew bolts for assembly mounting use stepladder -

– Remove bolts -arrows- of assembly mounting at engine.

– Remove bolts -arrows- of assembly mounting at gearbox.

♦ Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached.

♦ Carefully guide engine/gearbox assembly when lowering to avoid damage.

– Pull engine/gearbox assembly as far forward and to left as possible, and lower gradually.

2 Separating 6-speed manual gearbox 02S from engine

• Engine/gearbox assembly removed and attached to engine support -T10359-

– Attach lifting tackle -T40013- to gearbox and close lock.

– Attach workshop hoist -VAS 6100- with hooks -10 - 222 A /2- to the lifting tackle.

– Remove bolts -3 and 4- and detach starter.

– Remove bolts -1, 2, 5, 6, 7, 8- securing gearbox to engine.

3 Separating dual-clutch gearbox 02E from engine

• Engine/gearbox assembly removed and attached to engine support -T10359-

– Move electrical wiring clear -arrows-.

– Detach coolant hoses from gear oil cooler -arrows-.

Seal off open pipes/lines and connections with clean plugs or protective caps to prevent dirt from entering.

– Remove bolts -1 and 2- and detach starter.

– Slacken bolts -1- and remove bolts -2-.

– Screw eye-head bolt -3368- several turns into gearbox bracket and secure with self-locking flange nut M10 -arrow-.

– Attach lifting tackle -2024 A- to gearbox and workshop hoist -

VAS 6100- as shown in illustration.

To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown.

Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-.

– Remove bolts -1, 3, 5, 6, 7, 8, 9, 10- securing gearbox to en‐ gine.

4 Securing engine to engine and gearbox support

♦ Engine and gearbox sup‐ port -VAS 6095-

⇒ „2 Separating 6-speed manual gearbox 02S from engine“, page 31 or

⇒ „3 Separating dual-clutch gearbox 02E from engine“, page 33

– Engage lifting tackle -2024 A- on engine and workshop hoist

To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown.

Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-.

– Lift engine off engine and gearbox jack -VAS 6100- using workshop hoist -V.A.G 1383 A-

– Secure engine to engine and gearbox support -VAS 6095-

(gearbox end) as shown in illustration.

♦ Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.

♦ Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite.

♦ Do not use degreased parts.

Securing 6-speed manual gearbox 02S to engine

• 2) Also for starter to gearbox

Securing dual-clutch gearbox 02E to engine

• Bolts -2 and 4- secure starter to gearbox ⇒ Rep gr 27

Installation is carried out in the reverse order; note the following:

• Engine attached to engine support -T10359-

♦ Renew self-locking nuts and bolts.

♦ Renew bolts which are tightened to a specified angle as well as seals and gaskets.

♦ Secure all hose connections with the correct type of hose clips

(same as original equipment) ⇒ Electronic parts catalogue

– If not already fitted, install dowel sleeves for centring engine and gearbox in cylinder block.

– Ensure that intermediate plate is engaged on sealing flange and pushed onto dowel sleeves -arrows-.

– Guide engine/gearbox assembly into body.

– Tighten bolts securing engine mounting to engine support

Vehicles with 6-speed manual gearbox 02S:

– Tighten bolts securing gearbox mounting to gearbox bracket

The bolts are tightened to final torque only after adjusting the as‐ sembly mountings ⇒ page 42

– Detach engine support -T10359- from engine.

– Install heat shield for drive shaft ⇒ Rep gr 39

– Install swivel joints and drive shafts ⇒ Rep gr 40

– Installing and adjusting selector mechanism ⇒ Rep gr 34

Avoid damage to clutch slave cylinder.

♦ Do not operate clutch pedal with slave cylinder removed.

– Install clutch slave cylinder ⇒ Rep gr 30

– Install selector lever cable ⇒ Rep gr 34

– Install front exhaust pipe with catalytic converter

– Align the exhaust system so it is free of stress ⇒ page 253

– Install continued coolant circulation pump -V51-

– Install air conditioner compressor ⇒ Rep gr 87

– Install throttle valve module -J338- ⇒ Rep gr 24

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

– Install wiper arms ⇒ Rep gr 92

– Check oil level ⇒ Maintenance ; Booklet 810

Risk of irreparable damage to control units because of exces‐ sive voltage.

♦ Never use battery charging equipment for boost starting.

– Fill up with coolant ⇒ page 193

♦ Do not use drained coolant again if:

♦ the cylinder head or cylinder block have been renewed.

♦ The coolant is contaminated or dirty.

Checking adjustment of assembly mountings (engine/gearbox mountings)

Adjusting assembly mountings

❑ Version fitted in vehicle may differ from illustra‐ tion

❑ Engine support to en‐ gine

❑ Connecting bracket to engine mounting

❑ Engine mounting to engine support

❑ Gearbox mounting to gearbox bracket

❑ Illustration shows version for dual clutch gearbox 02E

6.2 Checking adjustment of assembly mountings (engine/gearbox mountings)

– Check distances at mounting (right-side) for engine and gear‐ box:

• The two bolt heads -2- must be parallel with edge of support arm -3- for engine mounting.

• There must be a distance of -x- = 16 mm between engine mounting -1- and engine support -4-.

Distance -x- = 16 mm can also be checked with a metal rod of suitable size, or similar.

– If the distance measured is too large or small, the assembly mountings must be adjusted ⇒ page 44

– Remove engine cover panel -arrows-.

– Detach air duct at bottom together with air hose.

– Release hose clip -1- and detach air hose.

– Unplug electrical connector -2- for air mass meter -G70-

– Unscrew air cleaner (top section) -arrow- and remove air filter element.

– Remove bolts -arrows- and detach air cleaner (bottom sec‐ tion).

– Remove bolts -arrows- and detach bracket for air cleaner housing.

– Hook spindle into engine lifting eye and take up weight of en‐ gine.

– Position support bracket -10 - 222 A- on top of body flanges using the following tools:

– Attach spindle -10 - 222 A /11- with adapter -10 - 222 A /20- and support hook from -2024 A- to gearbox lifting eye.

♦ The support hooks and retaining pins on the support bracket must be secured with locking pins -arrows-.

– Hook spindle -10 - 222 A /11- with lifting eye -2024 A /2- into engine lifting eye.

Illustration shows vehicle with dual clutch gearbox 02E.

– Take up weight of engine/gearbox assembly by evenly tight‐ ening two spindles.

– Remove bolts of assembly mounting at engine -arrows-.

– Remove bolts of assembly mounting at gearbox -arrows-.

– Renew each of the 4 or 5 bolts in turn (if not already done when installing engine) and hand-tighten.

– Slacken bolts on left and right-hand support arms by about two turns each.

– Using a tyre iron, adjust engine/gearbox assembly between engine support -1- and support arm -3- of engine mounting until the specifications listed below are obtained:

• The two bolt heads -2- must be parallel with edge of support arm -3- for engine mounting.

• There must be a distance of -x- = 16 mm between engine mounting -1- and engine support -4-.

Distance -x- = 16 mm can also be checked with a metal rod of suitable size, or similar.

– Tighten bolts of assembly mounting at gearbox.

– Ensure that edges of support arm (on gearbox side) -1- and gearbox mounting -2- are parallel.

• Dimension -x- must be identical on both sides of mounting.

– Ensure that edges of support arm (on gearbox side) -1- and gearbox mounting -2- are parallel.

• Dimension -x- must be identical on both sides of mounting.

– Tighten bolts for assembly mounting.

– Install air cleaner housing ⇒ Rep gr 24

Removing and installing tensioner for poly V-belt

Removing and installing bracket for ancillaries

Removing and installing vibration damper

1.1 Poly V-belt drive - exploded view

T10355- when loosen‐ ing and tightening

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen for re-installa‐ tion.

❑ When installing, make sure it is properly seated on pulleys.

❑ Pivot with open-end spanner to slacken poly V-belt

❑ Lock in position with locking pin -T10060 A-

❑ Components of tensioner for poly V-belt ⇒ page 50

❑ With oil filter and engine oil cooler

❑ Removing and installing bracket for ancillaries ⇒ page 55

❑ Removing and installing engine oil cooler ⇒ page 184

❑ Removing and installing ⇒ Rep gr 27

❑ Do not unscrew or disconnect refrigerant hoses or pipes

Components of tensioner for poly V-belt

Tightening sequence on bracket for ancillaries

– Fit bracket for ancillaries (first tighten bolt -4-).

– Tighten bolts in the sequence -1 5- in 3 stages as follows:

1.2 Removing and installing poly V-belt

– Lock tensioner with locking pin -T10060 A-

Secure alternator and air conditioner compressor before fitting poly-V-belt.

– Fit the poly V-belt onto the crankshaft and air conditioner com‐ pressor and alternator pulleys.

– Hold tensioner with ring spanner and remove locking pin -

– Check that poly V-belt is properly seated.

– Start engine and check that poly V-belt runs properly.

1.3 Removing and installing tensioner for poly V-belt

– Remove noise insulation (right-side) -arrows-.

– Remove bolt -2- at bracket for coolant pump for continued cir‐ culation -V51-

Disregard items marked -1 and arrows-.

– Remove bolts -arrows- of assembly mounting at engine.

– Lower engine by approx 55 mm.

– Detach poly V-belt from tensioner.

– Move electrical wiring harness clear -arrow-.

– Remove bolt -1- and take off tensioner for poly-V-belt from bracket for ancillaries.

⇒ „1.1 Poly V-belt drive - exploded view“, page 49

– Insert tensioner -1- for poly V-belt in bracket for ancillaries

• Note installation position of support element -2-: fit lug of sup‐ port element in hole on bracket for ancillaries.

• Note position of centring sleeve -4-.

– Install continued coolant circulation pump -V51-

1.4 Removing and installing bracket for an‐ cillaries

– Unplug electrical connector -1- for magnetic clutch on air con‐ ditioner compressor.

– Remove bolts -arrows- for air conditioner compressor.

– Tie up air conditioner compressor together with refrigerant ho‐ ses to longitudinal member (refrigerant hoses remain connec‐ ted).

– Remove bolt -arrow- for dipstick guide tube.

– Unscrew bolts -1 5- and detach bracket for ancillaries from coolant pump housing.

♦ Renew the bolts tightened with specified tightening angle.

– Lubricate O-rings -4- with coolant additive, for coolant additive refer to ⇒ Electronic parts catalogue

– Insert connection -2- into coolant pump housing -3-.

– Push bracket for ancillaries -1- onto connection, fit bolts and tighten ⇒ page 50

– Install air conditioner compressor ⇒ Rep gr 87

1.5 Removing and installing vibration damp‐ er

– Remove air pipe (lift clips -items 1 and 2-).

– Remove poly V-belt from pulley on vibration damper.

– Turn vibration damper to „TDC“ position -arrow- using coun‐ terhold tool -T10355-

• Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).

– Remove bolt for vibration damper using counterhold tool -

Risk of irreparable damage to engine.

♦ To avoid disturbing valve timing, do not turn crankshaft out of „TDC“ position when vibration damper is removed.

♦ Renew bolt for vibration damper.

♦ Hose connections and air pipes and hoses must be free of oil and grease before assembly.

– Lubricate sealing lip of oil seal with gear oil.

– Fit vibration damper (pay attention to shape of tooth -arrow-).

Sealing flange (gearbox end) and dual-mass flywheel - exploded view

Removing and installing sealing flange (gearbox end)

2.1 Sealing flange (gearbox end) and dual-mass flywheel - exploded view

❑ Removing and installing crankshaft ⇒ page 64

❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 70

❑ Renew only as com‐ plete unit

❑ Do not lubricate/grease sealing lip of oil seal

❑ Before installing, re‐ move oil residue from crankshaft journal with a clean cloth.

❑ Guide sleeve is not to be removed until sealing flange has been slipped onto crankshaft journal

❑ Must be positioned on dowel sleeves

❑ Do not damage/bend when assembling

❑ Is fitted onto sealing flange ⇒ page 60

❑ For dual-mass flywheel/drive plate

❑ Removing and installing dual-mass flywheel ⇒ page 60

❑ Can only be installed in one position Holes are off-set

Sealing flange (gearbox end) - tightening sequence

– Tighten bolts -1 to 8- in the sequence shown:

– 1 Screw in bolts finger-tight.

– Fit intermediate plate on sealing flange and push onto dowel sleeves -arrows-.

2.2 Removing and installing dual-mass fly‐ wheel

To avoid damaging the dual-mass flywheel during removal, it is crucial to refrain from using an impact wrench or similar tools on bolts -B- Instead, these bolts should only be removed by hand with conventional tools.

– Mark position of dual-mass flywheel in relation to engine.

– Rotate the dual-mass flywheel -A- so that the bolts -B- align centrally with the holes -arrows-.

When removing bolts, it is crucial to prevent the bolt heads from touching the dual-mass flywheel, as this contact can lead to damage of the flywheel during the unscrewing process.

– Insert counterhold -3067- in hole on cylinder block -B-.

⇒ „2.1 Sealing flange (gearbox end) and dual-mass flywheel - exploded view“, page 59

– Insert counterhold -3067- in hole on cylinder block -A-.

2.3 Removing and installing sealing flange

♦ Electric drill with plastic brush attachment

– Remove dual-mass flywheel ⇒ page 60

– Detach intermediate plate at sealing flange and dowel sleeves

– Remove sealing flange (gearbox end).

⇒ „2.1 Sealing flange (gearbox end) and dual-mass flywheel - exploded view“, page 59

♦ Silicone sealant ⇒ Electronic parts catalogue

♦ Note expiry date of silicone sealant.

♦ The sealing flange must be installed within 5 minutes after ap‐ plying silicone sealant.

– Remove sealant remaining on cylinder block with flat scraper.

– Remove sealant residue on sealing flange using rotating plas‐ tic brush or similar.

– Clean sealing surfaces; they must be free of oil and grease.

– Cut off nozzle of tube at front marking (∅ of nozzle approx 2 mm).

– Apply silicone sealant onto clean sealing surface of cover, as illustrated.

♦ Thickness of sealant bead: 2 3 mm.

♦ The sealing flange must be installed within 5 minutes after ap‐ plying the silicone sealant.

♦ The bead of sealant must not be thicker than specified, other‐ wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe.

– Fit guide sleeve -T20097- onto crankshaft journal.

– Push sealing flange over guide sleeve -T20097- onto crank‐ shaft journal and tighten bolts; tightening sequence

After installing the sealing flange, wait about 30 minutes for the sealant to dry Then (and only then) fill the engine with engine oil.

Further assembly is basically carried out in reverse order of dis‐ mantling.

Allocation of crankshaft bearing shells (classification)

Measuring radial clearance of crankshaft

Secure engine to repair stand using engine and gearbox support

-VAS 6095- when dismantling/assembling engine ⇒ page 36

2 - Bearing shell for cylinder block

❑ Do not interchange used bearing shells

❑ Identification of crank‐ shaft bearing shells

❑ After removing, place it down so that the sender wheel -item 5- is not damaged and the crank‐ shaft does not rest on the sender wheel

❑ If crankshaft is renewed, new bearing shells must be assigned to bearing caps ⇒ page 66

❑ Do not rotate the crank‐ shaft when checking the radial clearance

❑ Do not interchange used bearing shells

❑ Classification of crankshaft bearing shells ⇒ page 66

❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side

❑ Sender wheel must be renewed if bolts are loosened ⇒ page 65

❑ Can only be installed in one position Holes are off-set

❑ Sender wheel must be renewed if bolts are loosened

– Tighten crankshaft bolts in the sequence -1 5- as follows:

1 Screw in bolts -1 10- and -arrows- hand-tight.

2 Initially tighten bolts -1 10- to 65 Nm.

3 Turn bolts -1 10- 90° further using a rigid wrench.

4 Pre-tighten bolts -arrows- to 20 Nm.

5 Turn bolts -arrows- 90° further using a rigid wrench.

3.2 Removing and installing sender wheel

– Remove sealing flange (gearbox end) ⇒ page 61

– Remove upper section of sump ⇒ page 178

– Remove balance shaft timing chain ⇒ page 96

– Remove crankshaft and unbolt sender wheel.

– Sender wheel -2- must always be renewed after slackening off bolts -1-.

Re-tightening countersunk bolts can lead to deformation of the bolt head seats in the sender wheel, causing the bolt heads to contact the crankshaft.

-3- -arrows- and the sender wheel beneath the bolts will be loose.

♦ Sender wheel can only be fitted in one position because holes are offset.

3.3 Allocation of crankshaft bearing shells

Bearing shells of the correct thickness are allocated to the cylin‐ der block at the factory Coloured dots are used to identify the thickness of the bearing shells.

Letter codes on lower sealing surface or end of cylinder block indicate which bearing shell is to be fitted in cylinder block (top bearing shell) at each location.

Letter codes on crankshaft indicate which bearing shell is to be fitted in bearing cap (bottom bearing shell).

The first letter stands for bearing cap 1, the second letter for bear‐ ing cap 2, etc.

Marking of bearing shell for cylinder block:

Markings on cylinder block are applied either onto sealing surface for sump or gearbox end of cylinder block.

Marking on cylinder block refers to top bearing shell (bearing shell for cylinder block).

– Note down letters and refer to table for colour code to be fitted.

Marking of bearing shell for bearing cap:

Marking on crankshaft refers to bottom bearing shell (bearing shell for bearing cap).

– Note down letters and refer to table for colour code to be fitted.

1) Crankshaft main bearing journal ∅ Conrod journal ∅ Basic dimension 58.00 47.80

1) There is currently no provision for machining used crankshafts.

3.5 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket -VW 387-

– Bolt dial gauge -VAS 6079- with universal dial gauge bracket

-VW 387- onto cylinder block and set it against crank web.

– Press crankshaft against dial gauge by hand and set gauge to

– Push crankshaft away from dial gauge and read off value.

3.6 Measuring radial clearance of crank‐ shaft

♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.

– Remove main bearing caps and clean bearing caps and jour‐ nals.

– Place a length of Plastigage corresponding to the width of the bearing on the bearing journal or bearing shell.

• The Plastigage must be positioned in the centre of the bearing

– Fit main bearing caps and tighten to 60 Nm without rotating crankshaft.

– Remove main bearing cap again.

– Compare width of Plastigage with measurement scale.

⇒ „4.1 Pistons and conrods - exploded view“, page 70

Piston and cylinder dimensions

4.1 Pistons and conrods - exploded view

❑ On vehicles with 1.8 ltr. engine: 30 Nm + turn

❑ On vehicles with 2.0 ltr. engine: 45 Nm + turn

❑ Lubricate threads and contact surface

❑ Use old bolts when measuring radial clear‐ ance

❑ To measure radial clear‐ ance, tighten to 30 Nm but do not turn further

The unique cracking method employed in the manufacturing process ensures that bearing caps are designed to fit exclusively in one specific position on their corresponding conrods.

Marking -B- faces to‐ wards pulley end

❑ Do not interchange used bearing shells (mark positions)

❑ Axial clearance when new: 0.10 0.35 mm; wear limit: 0.40 mm

❑ Check radial clearance with Plastigage - (new): 0.02 0.06 mm; wear limit: 0.09 mm Do not turn crank‐ shaft when measuring radial clearance

❑ Remove and install using drift -VW 222 A-

❑ Mark installation position and cylinder number

❑ Arrow on piston crown points to pulley end

❑ Install using piston ring clamp

❑ Piston and cylinder dimensions ⇒ page 73

❑ Use piston ring pliers to remove and install

❑ „TOP“ or „R“ must face towards piston crown

❑ Checking ring-to-groove clearance ⇒ page 71

❑ Offset gap of top steel element of piston ring by 120° to next compression ring.

❑ Offset gaps of individual parts of oil scraper ring.

❑ Ring-to-groove clearance cannot be checked.

❑ Only renew as a complete set

❑ Installation position: Marking -B- faces towards pulley end

❑ Separating parts of new conrod ⇒ page 73

To properly insert a ring into a cylinder, position it at a right angle to the cylinder wall from above and gently push it down into the lower opening, approximately 15 mm from the bottom Utilize a piston without rings to effectively push the ring into the bore.

Dimensions in mm New Wear limit

Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.

Dimensions in mm New Wear limit

Oil scraper rings Cannot be measured

– Measure pistons approx 10 mm from the lower edge of skirt, at 90° to the piston pin axis.

♦ Difference between actual and nominal diameter: not more than 0.04 mm.

Machining (reboring, honing, grinding) cylinder bore with work‐ shop equipment is not permitted The surface of the cylinder bore is damaged by machining.

– Take measurements at 3 positions in both lateral direction

♦ Difference between actual and nominal diameter: not more than 0.08 mm.

Measuring the cylinder bores must not be done when the cylinder block is mounted to the engine and gearbox stand -VAS 6095- , as incorrect measurements may result.

Installation position of bearing shell

– Position bearing shells in centre of conrod and conrod bearing cap when fitting.

Dimension -a- must be identical on both sides.

4.2 Separating parts of new conrod

If the conrod bearing cap cannot be removed by hand, it may indicate that the two parts of the new conrod are not fully separated as intended To address this issue, follow the appropriate steps to safely detach the conrod bearing cap.

– Mark cylinder allocation of conrod ⇒ Item 11 (page 71)

– Clamp the conrod lightly in a vice using aluminium jaw covers as shown in illustration.

♦ To avoid any risk of damage, the conrod should only be clam‐ ped lightly.

♦ The conrod is clamped in a position below the dotted line.

– Unscrew the two bolts -arrows- approx 5 turns.

– Using a plastic hammer, carefully knock conrod bearing cap loose in direction of -arrow-.

• 1) Dimensions not including graphite coating (thickness 0.02 mm) The graphite coating will wear down in service.

Removing and installing camshaft control valve 1 N205

Removing and installing timing chain cover (top)

Removing and installing timing chain cover (bottom)

Removing and installing camshaft timing chain

Removing and installing balance shaft timing chain

Renewing balance shaft for exhaust camshaft

Checking valve timing

1.1 Timing chain cover - exploded view

2 - Guide tube for oil dipstick

Timing chain cover (top) - tightening sequence

– Tighten bolts -1 to 5- in the sequence shown:

Timing chain cover (bottom), tightening sequence

– Tighten bolts -1 to 15- in two stages in the sequence shown:

1.2 Removing and installing camshaft con‐ trol valve 1 -N205-

– Detach connector from camshaft control valve 1 -N205- -1-.

– Unscrew bolts -arrows- and remove camshaft control valve 1

⇒ „1.1 Timing chain cover - exploded view“, page 75

– Lubricate seal and O-ring with engine oil.

1.3 Removing and installing timing chain cover (top)

♦ Open-end spanner insert AF 10 -V.A.G 1783/1-

– Unscrew bolts -1 to 5- and remove timing chain cover (top).

⇒ „1.1 Timing chain cover - exploded view“, page 75

– Lubricate seal and O-ring with engine oil.

– Install timing chain cover (top) using torque wrench -V.A.G

1783- and open-end spanner insert AF 10 -V.A.G 1783/1- , tightening sequence ⇒ page 76

– Install camshaft control valve 1 -N205- ⇒ page 76

1.4 Removing and installing timing chain cover (bottom)

– Remove bolts -arrows- and detach bracket for activated char‐ coal filter.

♦ Move electrical wiring clear at coolant expansion tank.

♦ Unplug electrical connector -1- at coolant shortage indicator switch -F66-

♦ Remove bolts -arrows- and move coolant expansion tank to one side (coolant hoses remain attached).

Always use thrust piece -T10368- when fitting bolt for vibration damper to avoid damaging splines.

– Fit bolt for vibration damper and thrust piece -T10368- again.

♦ To avoid disturbing valve timing, do not turn crankshaft out of „TDC“ position when bolt for vibration damper is re‐ moved.

– Remove bolts -1 and 2- and detach connecting bracket.

– Remove bolts -3 6- and detach engine mounting.

– Raise engine approx 50 mm and loosen top bolt on engine support.

– Now lower engine by approx 100 mm.

– Move electrical wiring harness clear -arrow-.

– Remove bolt -1- and take off tensioner for poly-V-belt from bracket for ancillaries.

– Remove bottom bolts for engine support using bits -T10099-

– Remove engine support with bolts.

– Remove bolts -arrows- and detach guide tube for oil dipstick from timing chain cover.

– Remove charge pressure control solenoid valve -N75- from turbocharger -arrows-.

– Lever off timing chain cover (bottom) (start at points

To prevent damaging the timing chain cover, apply tool only at the bolt holes.

⇒ „1.1 Timing chain cover - exploded view“, page 75 ,

⇒ „6.1 Assembly mountings - exploded view“, page 42

♦ The cover must be installed within 5 minutes after applying the silicone sealant.

♦ Renew seals, gaskets and self-locking nuts.

– Spray sealing surface with sealant remover and wait for it to take effect.

– Mask oil seal on both sides with adhesive tape to make sure the seal remains clean.

– Remove remaining sealant from cover (e.g with rotating plas‐ tic brush or similar).

– Use old bolts when fitting cover and tighten to 8 Nm.

– Use feeler gauge to measure distance between cover and crankcase (max distance is 0.2 mm).

♦ Renew cover if distance exceeds 0.2 mm.

♦ It is not possible to measure distance between cover and sump

(top section); check visually to ensure that sealing surface is even.

– Check that both dowel pins are fitted in cover -arrows-.

– Apply silicone sealant onto clean sealing surface of cover, as illustrated.

– Immediately fit timing chain cover and tighten bolts; tightening sequence ⇒ page 76

After fitting cover, let sealant dry for approx 30 minutes Then

(and only then) fill the engine with engine oil.

– Install poly V-belt tensioner ⇒ page 52

1.5 Renewing oil seal for vibration damper

♦ To avoid disturbing valve timing, do not turn crankshaft out of „TDC“ position when vibration damper is removed.

– Detach vibration damper and fit thrust piece -T10368- in its place.

– Pull out oil seal using extractor tool -T20143/2-

– Clean contact surface and sealing surface.

– Use thrust piece -T10354- and bolt for vibration damper to pull in oil seal -arrow- onto stop.

♦ Renew bolt for vibration damper.

1.6 Camshaft timing chain - exploded view

❑ Before removing, lock in place using locking pin -

3 - Tensioning rail for timing chain

❑ Remove using assem‐ bly tool -T10352-

10 - Guide rail for camshaft tim‐ ing chain

❑ Before removing, mark running direction with paint

13 - Guide rail for camshaft timing chain

Crankshaft chain sprocket - installation position

• The two sections -arrows- must be aligned.

1.7 Removing and installing camshaft tim‐ ing chain

♦ Assembly tool -T10352- and assembly tool -T10352/1-

– Remove timing chain cover (top) ⇒ page 76

The timing valve has a left-hand thread.

– Depending on version, turn assembly tool -T10352- or assem‐ bly tool -T10352/1- in direction of -arrow- to remove timing valve.

– Remove bolts -arrows- and detach bearing saddle.

• The markings -1- on the camshafts must face upwards.

– Remove timing chain cover (bottom) ⇒ page 78

– Press oil pump chain tensioner in direction of -arrow- and lock in place using locking pin -T40011-

– Remove oil pump chain tensioner -1-.

– Insert scriber or suitable screwdriver in hole of chain tensioner in direction of -arrow 1- and lift locking element for chain ten‐ sioner.

– Press tensioning rail for timing chain in direction of -arrow 2- and lock in place using locking pin -T40011-

– Detach camshaft timing chain from cylinder head.

Inlet camshaft will move in direction of engine rotation.

– Remove tensioning rail for timing chain -2-.

– Remove guide rail for camshaft timing chain -1-.

⇒ „1.6 Camshaft timing chain - exploded view“, page 88

♦ The following procedure must be performed in one operation; this requires the assistance of a second mechanic.

♦ The timing chain links with coloured markings must be posi‐ tioned at the markings on the chain sprockets.

♦ Hold spanner in position until tensioning rail is installed.

– Check TDC position of crankshaft.

– Fit timing chain onto exhaust camshaft.

– Fit timing chain onto crankshaft.

– Use spanner to turn inlet camshaft in direction of -arrow- and fit timing chain.

– Fit tensioning rail for timing chain and tighten bolt -2-.

– Fit guide rail for camshaft timing chain and tighten bolts -1-.

– Attach bearing saddle and screw in bolts -arrows- hand-tight.

– Tighten bolts -arrows- for bearing saddle ⇒ page 88

– Install timing valve ⇒ Item 6 (page 88)

Perform further installation in reverse order, paying attention to the following:

– Install timing chain cover (bottom) ⇒ page 78

– Install timing chain cover (top) ⇒ page 76

1.8 Balance shaft timing chain - exploded view

❑ Lubricate bearing with engine oil

❑ If bolt ⇒ Item 12 (page 94) was slackened, idler gear must be renewed

❑ If bolt was slackened, idler gear ⇒ Item 9 (page 94) must be renewed

❑ For balance shaft timing chain

Tube for balance shaft - installation position

• Lug on tube for balance shaft must engage in slot -arrow-.

• Renew O-ring -1- and lubricate with oil.

• Dowel pin -arrow- for bearing mounting must engage in bore in cylinder block.

Always renew idler gear If this is not done, there is no back‐ lash, which causes engine damage.

The new idler gear has a special lubricant coating, which wears off after a short running period and thus automatically creates the specified backlash.

– Secure with new bolt as follows:

1 Tighten with torque wrench initially to 10 Nm.

Idler gear must be without play; otherwise loosen bolt and tighten again.

3 Tighten with torque wrench to 25 Nm.

4 Use rigid wrench to turn 90° further.

1.9 Removing and installing balance shaft timing chain

– Remove camshaft timing chain ⇒ page 89

– Remove chain tensioner for camshaft timing chain -3-.

– Remove chain tensioner for balance shaft timing chain -1-.

– Turn idler gear/balance shaft to markings -arrows-.

The timing chain links with coloured markings must be positioned at the markings on the chain sprockets.

– Fit timing chain; the timing chain links with coloured markings must be positioned at the markings on the chain sprockets.

– Fit guide rail for timing chain and tighten bolts -4-.

– Fit guide rail for timing chain and tighten bolts -3-.

– Fit tensioning rail for timing chain and tighten bolt -2-.

– Apply locking fluid and fit chain tensioner for timing chain -1-; for locking fluid refer to ⇒ Electronic parts catalogue

– Check markings on idler gear/balance shaft -arrow-.

For illustration purposes, the markings on the idler gear/balance shaft are shown with the chain removed.

– Install camshaft timing chain ⇒ page 89

1.10 Renewing balance shaft for inlet cam‐ shaft

Always renew balance shaft for inlet camshaft after removal.

– Remove toothed belt for coolant pump ⇒ page 208

– Remove bolt -2- securing balance shaft for inlet camshaft.

– Insert half shell -T10394/1- of puller -T10394- and turn up‐ wards in direction of arrow.

– Insert puller -T10394- and press locking collar in direction of

– Screw puller -T10055- into puller -T10394- and knock out bal‐ ance shaft in direction of -arrow-.

Before installing the balance shaft, it may be necessary to cool it due to the tight clearance with the cylinder block Ensure that the balance shaft can be inserted into the cylinder block without force; if not, cooling the balance shaft prior to installation is essential.

⇒ „1.8 Balance shaft timing chain - exploded view“, page 94

– Put new balance shaft for 30 minutes into freezer compart‐ ment or spray with chilling agent (commercially available) if necessary.

– Lubricate balance shaft bearing with engine oil.

– Install new balance shaft for inlet camshaft and tighten bolt

– Renew O-ring -1- and lubricate with engine oil.

– Lubricate bearing mounting with engine oil and install; dowel pin -arrow- for bearing mounting must engage in bore in cyl‐ inder block.

Always renew idler gear If this is not done, there is no back‐ lash, which causes engine damage.

The new idler gear has a special lubricant coating, which wears off after a short running period and thus automatically creates the specified backlash.

– Mark faces of gear teeth of idler gear with paint marker

– Insert idler gear Marking on balance shaft must be positioned between markings on faces of gear teeth.

– Tighten bolt -1- for idler gear: tightening sequence

– Check markings on idler gear/balance shaft -arrow-.

On account of the ratio the markings only align every 7th revolu‐ tion.

– Install balance shaft timing chain ⇒ page 96

– Renew oil seal for coolant pump drive ⇒ page 210

– Install toothed belt for coolant pump ⇒ page 208

1.11 Renewing balance shaft for exhaust camshaft

Always renew balance shaft for exhaust camshaft after removal.

– Remove bolt -1- securing balance shaft for outlet camshaft.

– Insert half shell -T10394/1- from puller -T10394-

– Insert puller -T10394- and press locking collar in direction of

– Screw puller -T10055- into puller -T10394- and knock out bal‐ ance shaft.

Before installation, it may be essential to cool the balance shaft due to the tight clearance with the cylinder block Ensure that the balance shaft can be inserted into the cylinder block without force; if not, cooling the balance shaft prior to installation is necessary.

⇒ „1.8 Balance shaft timing chain - exploded view“, page 94

– Check installation position of tube for balance shaft -arrow-.

Lug -arrow- must engage in slot.

– Put new balance shaft for 30 minutes into freezer compart‐ ment or spray with chilling agent (commercially available) if necessary.

– Lubricate balance shaft bearing with engine oil.

– Make sure that balance shaft is in full contact with crankcase before tightening bolt -1-.

Repeat insertion of tube for balance shaft if the balance shaft is not in full contact.

Further assembly is basically carried out in reverse order of dis‐ mantling Note the following:

– Install balance shaft timing chain ⇒ page 96

– Remove timing chain cover (top) ⇒ page 76

– Working from below, turn vibration damper in direction of en‐ gine rotation to „TDC“ position -arrow-.

To turn the vibration damper, use a ratchet with 24 mm socket.

Always turn vibration damper to „TDC“ in normal direction of ro‐ tation Do NOT move back to TDC position by turning in reverse direction.

• Notch on vibration damper must align with arrow marking on bottom cover for timing chains (use a mirror).

• The markings -1- on the camshafts must face upwards.

– Measure distance from outer edge of rib -A- to marking -B- on inlet camshaft.

– If specification is obtained, measure distance between mark‐ ing on inlet camshaft -B- and marking on exhaust camshaft

A misaligned timing chain, even by just one tooth, can lead to a deviation of approximately 6 mm from the specified alignment It is essential to refit the timing chain to ensure it is positioned correctly.

Removing and installing cylinder head without AVS

Removing and installing cylinder head with AVS

2.1 Cylinder head without AVS - exploded view

♦ Renew the cylinder head bolts.

♦ During assembly, renew oil seals and gaskets as well as self- locking nuts and bolts that are tightened by turning through to a specified angle.

♦ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.

♦ After fitting a new cylinder head or cylinder head gasket, change the engine oil and the coolant in the entire cooling system.

❑ Note installation posi‐ tion: part number must face cylinder head

❑ Note correct sequence when loosening

❑ Note correct sequence when tightening

❑ Note correct sequence when loosening

❑ Note correct sequence when tightening

❑ With ball head for engine cover panel

❑ Note correct sequence when tightening ⇒ page 108

Crankcase breather system - tightening torque

When renewing the cylinder head, it is crucial to use genuine thread-forming bolts, as the cylinder head does not come with threaded holes for attaching the crankcase breather.

♦ Do NOT make threaded holes using a thread tap.

– Tighten bolts for crankcase breather system in the sequence

– Slacken cylinder head bolts in the sequence -1 5-.

Tightening sequence for cylinder head

– Tighten cylinder head bolts in the sequence -1 5- as follows:

Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure cylinder head for distortion at several points.

2.2 Removing and installing cylinder head without AVS

– Remove front exhaust pipe with catalytic converter

– Remove bolt -1- and take out air pipe downwards.

– Unplug electrical connectors -1 and 2- and move electrical wire clear -arrows-.

– Remove bolts -1 and 2- and detach support for turbocharger.

– Remove banjo bolt -2- and move coolant pipe clear to one side.

– Remove bolts -1- on oil return line.

– Remove bolt -3- on oil supply line.

– Remove bolts -arrows- and detach crankcase breather.

– Detach electrical connector -4- and move wiring harness clear.

– Detach vacuum hose -5- from exhauster pump and move clear.

– Unscrew bolt -3- and detach coolant pipe.

– Remove oil supply line from turbocharger -1-.

– Unplug electrical connectors at ignition coils and move wiring harness clear.

– Remove ignition coils using puller -T40039-

– Disconnect coolant hoses on rear of cylinder head.

– Detach vacuum line -6- leading to activated charcoal filter.

– Unplug electrical connectors -1- and detach connectors from retainer.

– Detach coolant pipe from intake manifold; to do so, unscrew bolts -arrows-.

– Remove intake manifold support (remove securing nut -1- and bolt -2-).

Protect fuel system against contamination.

♦ Rules for cleanliness when working on the injection sys‐ tem ⇒ page 6

• Notch on vibration damper must align with arrow marking on bottom cover for camshaft timing chain.

– Use a waterproof pen to mark camshaft timing chain and cyl‐ inder head -arrows- to markings on chain sprocket -1-.

– Turn crankshaft in opposite direction to normal rotation

-arrow 2- and lock in place using locking pin -T40011-

– Remove bolt -1- and detach tensioning rail -2- downwards.

– Use screwdriver to release catch and press off top guide rail

– Remove camshaft timing chain from camshaft sprockets.

Avoid damage to valves and piston crowns.

♦ Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head.

– Turn sealing plugs -arrows- 90° anti-clockwise -arrow- and re‐ move.

– Remove cylinder head bolts in the sequence -1 5-.

♦ If necessary, use spanner to turn camshafts before removing cylinder head bolts.

♦ Make sure all hoses/pipes and wiring on component are re‐ moved.

♦ Make sure tensioning rail and guide rail are not damaged when lifting off cylinder head.

– Place cylinder head onto soft surface (foam plastic).

⇒ „2.1 Cylinder head without AVS - exploded view“, page 105

Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and cylinder block.

♦ Ensure that no long scores or scratches are made on the surfaces.

Avoid damage to cylinder block.

♦ No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.

Ensure that cylinder head gasket seals properly:

♦ Carefully remove any remaining emery and abrasive ma‐ terial.

♦ Do not remove new cylinder head gasket from packaging until it is ready to be fitted.

♦ Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket.

Avoid damage to open valves.

♦ When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted.

Avoid damage to valves and piston crowns after working on valve gear.

♦ Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is op‐ erated.

♦ Renew self-locking nuts as well as seals, gaskets and O-rings.

♦ When installing an exchange cylinder head, the contact sur‐ faces between the hydraulic compensation elements, roller rocker fingers and cams must be oiled before installing the camshaft housing.

♦ To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing.

– Place cylinder head gasket in position.

♦ Note position of centring pins in cylinder block -arrows-.

♦ Note installation position of cylinder head gasket Part No. should be legible from inlet side.

Make sure that components are not damaged by the timing chain when rotating the crankshaft.

– If crankshaft has been rotated: set No 1 cylinder piston to top dead centre and then turn crankshaft back slightly.

– Insert and hand-tighten cylinder head bolts.

Turn inlet camshaft using spanner to fit cylinder head bolts.

– Tightening sequence for cylinder head ⇒ page 108 :

Cylinder head bolts do not have to be torqued down again later after repair work.

The camshaft timing chain links with markings must be positioned at the markings on the chain sprockets and on the cylinder head.

– Use spanner to turn inlet camshaft in direction of -arrow- and fit camshaft timing chain Markings on camshaft timing chain and cylinder head -arrows- must align with chain sprockets

The remaining installation steps are carried out in the reverse se‐ quence Note the following points:

– Change engine oil ⇒ Maintenance ; Booklet 810

– Fill cooling system with fresh coolant ⇒ page 191

Never use battery charging equipment for boost starting There is danger of damaging the vehicle's control units.

2.3 Cylinder head with AVS - exploded view

♦ Renew the cylinder head bolts.

♦ During assembly, renew oil seals and gaskets as well as self- locking nuts and bolts that are tightened by turning through to a specified angle.

♦ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.

❑ Note installation posi‐ tion: part number must face cylinder head

❑ Note procedure when loosening ⇒ page 125

❑ Note procedure when tightening ⇒ page 126

❑ Note procedure when loosening ⇒ page 125

❑ Note procedure when tightening ⇒ page 126

8 - Actuator for variable valve timing

❑ With ball head for engine cover panel

Crankcase breather system - tightening torque

When replacing the cylinder head, it is crucial to use genuine thread-forming bolts, as the cylinder head does not come with threaded holes for attaching the crankcase breather.

♦ Do NOT make threaded holes using a thread tap.

– Tighten bolts for crankcase breather system in the sequence

Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure cylinder head for distortion at several points.

– Slacken cylinder head bolts in the sequence -1 10-.

Tightening sequence for cylinder head

– Tighten cylinder head bolts in the sequence -1 10- as fol‐ lows:

2.4 Removing and installing cylinder head with AVS

♦ Do not turn the crankshaft after the camshafts have been removed.

– Detach electrical connector -4- and move wiring harness clear.

– Detach vacuum hose -5- from exhauster pump and move clear.

– Unscrew bolt -3- and detach coolant pipe.

– Disconnect coolant hoses on rear of cylinder head.

– Detach vacuum line -6- leading to activated charcoal filter.

– Unplug electrical connectors -1- and detach connectors from retainer.

– Detach coolant pipe from intake manifold; to do so, unscrew bolts -arrows-.

– Remove intake manifold support (remove securing nut -1- and bolt -2-).

Protect fuel system against contamination.

♦ Rules for cleanliness when working on the injection sys‐ tem ⇒ page 6

– Remove cylinder head bolts in the sequence -1 10-.

♦ Make sure all hoses/pipes and wiring on component are re‐ moved.

♦ Make sure tensioning rail and guide rail are not damaged when lifting off cylinder head.

– Place cylinder head onto soft surface (foam plastic).

⇒ „2.3 Cylinder head with AVS - exploded view“, page 123