Engine 2.0 103 Kw Tdi Pd, 2.0 100 Kw Tdi Pd

Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5709.00.20

Workshop ManualOCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PDEdition 02.04Engine code BKD AZV

Service5

The Workshop Manual is intended only for use within the Organisation koda.It is not permitted to pass it on to other persons.

KODA AUTO a. s.

Printed in Czech RepublicS00.5709.00.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

List of SupplementsEdition 01.05S00.5709.01.20

List of Supplements to Workshop ManualOCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PDEdition 02.04

Supple-ment Edition Subject Article Number

02.04 Basic Edition S00.5709.00.201 01.05 Supplement to engines with the engine codes AZV S00.5709.01.20


List of Supplements Edition 01.05S00.5709.01.20


Table of ContentsEdition 01.05S00.5709.01.20

I

Table of Contents

00 Technical DataTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Engine number ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Engine characteristics .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 Self-diagnosisSelf diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . . .- Supplementary instructions and assembly work on vehicles with an air conditioning

system ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Safety precautions when working on the fuel supply system ......... . . . . . . . . . . . . . . . . . . . . . . . . . .- Regulations concerning cleanliness when working on the fuel supply/fuel injection system- Regulations concerning cleanliness when working on the exhaust gas turbocharger ... ...

10 Removing and Installing EngineRemoving and Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Securing the engine to the assembly stand ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Installing ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Adjust assembly bracket ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Assembly bracket .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CrankgearDisassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing V-ribbed belt ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing timing belt ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing gasket ring for crankshaft -on the belt pulley side- .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the front sealing flange ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replace rear sealing flange ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the two-mass flywheel ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replace needle bearing for crankshaft ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing crankshaft .. .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling piston and conrod ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking piston projection in TDC .... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Cylinder Head, Valve GearRemoving and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- removing and installing cylinder head cover ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing cylinder head ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Installing ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing the compression ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the axial play of the camshafts .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing camshaft gasket rings ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-1 page 100-1 page 100-1 page 1

01-1 page 1

01-1 page 101-1 page 101-1 page 201-1 page 2

10-1 page 110-1 page 110-1 page 410-1 page 510-1 page 810-1 page 8

13-1 page 113-1 page 113-1 page 4



15-1 page 115-1 page 215-1 page 315-1 page 515-1 page 615-1 page 915-1 page 12

15-2 page 115-2 page 215-2 page 3


Table of Contents Edition 01.05S00.5709.01.20II

- Removing and installing camshafts ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing valve lever ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check hydraulic supporting elements ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing valve stem seals ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Valve dimensions ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspect valve guides ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 LubricationRemoving and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling oil filter holder ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing oil pan ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing oil pump ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing oil pressure and oil pressure switch ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 CoolingRemoving and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Parts of the cooling system fitted to body ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Parts of cooling system engine side ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for coolant hoses ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Draining and filling up coolant ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing coolant pump ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing coolant regulator .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing radiator ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing radiator fan -V7- and -V177- ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the coolant system for tightness ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Fuel SupplyRemoving and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Fuel tank with attached parts .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing fuel filter ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing fuel cooler ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel tank ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check the fuel delivery unit ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel delivery unit ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel gauge sender -G- ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the tandem pump ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspecting a tandem pump ....... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Accelerator pedal module - Summary of components .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing accelerator pedal module ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 TurbochargingCharge-air system with exhaust turbocharger - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for vacuum hoses ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for valve block ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspect vacuum setting element and tension rods for charge pressure control .... .. . . . . . . .

Charge-air system with exhaust turbocharger - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing turbocharger ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing parts of the charge air cooling ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


17-1 page 117-1 page 317-1 page 417-1 page 617-1 page 6

19-1 page 119-1 page 219-1 page 319-1 page 519-1 page 519-1 page 819-1 page 819-1 page 1019-1 page 1119-1 page 12

20-1 page 120-1 page 120-1 page 320-1 page 320-1 page 420-1 page 520-1 page 720-1 page 820-1 page 920-1 page 10

20-2 page 120-2 page 120-2 page 1


21-2 page 121-2 page 121-2 page 4


Table of ContentsEdition 01.05S00.5709.01.20

III

- Removing and installing charge-air cooler .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing air filter ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 Fuel Formation, InjectionRepairing a diesel direct fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Safety measures ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Overview of fitting locations ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Overview of intake manifold .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Repairing the unit injectors ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the unit injectors ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replace O-rings for unit injectors ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing engine control unit . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 Exhaust SystemRemoving and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing middle or rear silencer ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Aligning exhaust system free of stress ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the exhaust system for leaks ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing parts of the exhaust gas recirculation system ..... .... . . . . . . . . . . . . .- Connection diagram for exhaust gas recirculation ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for valve block ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Test mechanical exhaust gas recirculation valve ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Cool the exhaust gas recirculation .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check exhaust gas recirculation changeover ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing radiator for exhaust gas recirculation ....... . . . . . . . . . . . . . . . . . . . . . . . . .

28 Glow Plug SystemPreheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing glow plugs .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21-2 page 521-2 page 7

23-1 page 123-1 page 123-1 page 223-1 page 323-1 page 423-1 page 523-1 page 9

23-2 page 123-2 page 1

26-1 page 126-1 page 226-1 page 226-1 page 326-1 page 4

26-2 page 126-2 page 226-2 page 326-2 page 326-2 page 426-2 page 426-2 page 426-2 page 5

28-1 page 128-1 page 1


Table of Contents Edition 01.05S00.5709.01.20IV


Technical DataEdition 01.05S00.5709.01.20

00-1 page 1

00

00-1 Technical Data

Engine numberThe engine number (engine identification characters and serial number) is located in the front at the engine/gearbox joint -arrow-.

In addition, a sticker with the engine identification char-acters and serial number is affixed to the timing belt guard.

The engine identification characters are also indicated on the vehicle data stickers.

Engine characteristics

00 Technical Data

Engine identification char-acters

BKD AZV

Manufactured 05.04 10.04 Exhaust limits conforming to EU4 EU4Displacement l 1,968 1,968Power output kW at

rpm103/4000 100/4000

Torque Nm atrpm

320/1750 2500

320/1750 2500

Bore mm 81,0 81,0Stroke mm 95,5 95,5Number of valves per cylinder 4 4Compression 18,5 : 1 18,5 : 1CN min. 49 49Firing order 1-3-4-2 1-3-4-2Catalytic con-verter

yes yes

Exhaust gas recirculation with radiator

yes yes

Turbocharg-ing

yes yes

Charge air cooler yes yes


Technical Data Edition 01.05S00.5709.01.2000-1 page 2

00


Self diagnosis, safety measures, cleanliness regulations and directions

Edition 02.04S00.5709.00.20

01-1 page 1

01

01-1 Self diagnosis, safety measures, cleanliness regulations and directions

Supplementary instructions and assem-bly work on vehicles with an air condi-tioning system

In order to avoid damage to the condenser as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent.

Steps which should be taken in order to remove and in-stall the engine without opening the refrigerant circuit.

Unscrew the holding clamp(s) on the refrigerent lines Remove the V-ribbed belt Chapter 13-1. Remove the air-conditioning compressor Chapter

13-1. Mount the air conditioning compressor and the con-

denser in such a way that the refrigerent lines/hoses are not under tension.

Safety precautions when working on the fuel supply system

When removing and installing the fuel gauge sender from a full or partly filled fuel tank, pay attention to the follow-ing:

The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the assembly opening of the fuel tank in order to extract

01 Self-diagnosis

WARNING!

Do not open the refrigerant circuit of the air condi-tioning system.

Note

WARNING!

Please observe the following when undertaking all assembly work, particularly in the engine compart-ment, due to its cramped construction.

Lay lines of all kinds (e.g. for fuel, hydraulic flu-id, cooling fluid and refrigerent, brake fluid, vacuum) and electrical lines in such a way that the original line guide is re-established.

Ensure that there is adequate free access to all moving or hot components.


Self diagnosis, safety measures, cleanliness regulations and directions

Edition 02.04S00.5709.00.2001-1 page 2

01

the released fuel gases, even before the work is com-menced. If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m3/h must be used.

Avoid skin contact with fuel! Wear fuel-resistant gloves!

Regulations concerning cleanliness when working on the fuel supply/fuel in-jection systemCarefully observe the following 6 rules for cleanliness when working on the fuel supply/injection system:

Thoroughly clean the connection points and their sur-roundings before releasing.

Place removed parts on a clean surface and cover. Do not use fuzzy cloths!

Carefully cover or close opened components if the re-pair is not completed immediately.

Only install clean parts: Remove spare parts from their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. on a shelf or in a tool box).

When the system is open: Avoid using compressed air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant hoses. If this is the case clean the hoses immediately. Replace immediately any hoses which have suffered damage.

Regulations concerning cleanliness when working on the exhaust gas turbo-chargerCarefully observe the following 5 rules for cleanliness when working on the exhaust turbocharger:

Thoroughly clean the connection points and their sur-roundings before releasing.

Place removed parts on a clean surface and cover. Do not use fuzzy cloths!

Carefully cover or close opened components if the re-pair is not completed immediately.

Only install clean parts: Remove spare parts from their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. on a shelf or in a tool box).

When the system is open: Avoid using compressed air. Avoid moving the vehicle.


Removing and Installing EngineEdition 01.05S00.5709.01.20

10-1 page 1

10

10-1 Removing and Installing Engine

Special tools, test and measuring equipment and auxiliary items required

Catch pan (e.g. -V.A.G 1306-) Engine/gearbox jack (e.g. -V.A.G 1383 A -) Engine mount -T10012- Workshop crane (e.g. -V.A.G 1202 A-) Double ladder (e. g. -VAS 5085-) Hose clamp -MP 7-602- Pliers for spring strap clips

Removing

The engine is removed downwards together with the gearbox.

All cable straps that have been loosened or cut open when the engine was removed must be fitted again in the same location when the engine is installed again.

Collect drained coolant in a clean container for proper disposal or reuse.

Pull oil dipstick -1- out of oil dipstick guide. Lift the engine cover at the sides -arrows 1- and pull

out towards the front -arrow 2-. Push the oil dipstick back into the oil dipstick guide.

Disconnect the battery-earth strap with the ignition off Electrical System; Rep. Gr. 27.

Remove cover and intermediate wall of the plenum chamber Body Work; Rep. Gr. 66.

Remove air filter and air guide with air mass meter Chapter 21-2.

Remove battery and battery tray Electrical System; Rep. Gr. 27.

Remove both front wheels Chassis; Rep. Gr. 44. Remove the middle sound dampening system Body Work; Rep. Gr. 50.

10 Removing and Installing Engine

Note

WARNING!

Observe measures when disconnecting the battery Electrical System; Rep. Gr. 27.


Removing and Installing Engine Edition 01.05S00.5709.01.2010-1 page 2

10

Drain coolant Chapter 19-1.

Detach coolant hose, fuel-intake hose -2- and fuel-re-turn hose -1- from pipes at cylinder head.

Detach fuel filter with its connected hoses upwards from the bracket -arrow- and lay to the side.

Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.

Remove the V-ribbed belt Chapter 13-1. Remove alternator Electrical System; Rep. Gr. 27.On vehicles with air conditioning:

In order to avoid damage to the AC condenser as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent.

Removing AC compressor and holder for auxiliary units Chapter 13-1.

Tie up removed AC compressor with connected refrig-erant hoses to the body.

Continued for all vehicles:

Remove charge air hose and charge-air pipe between engine and charge air cooler Chapter 21-2.

WARNING!

Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully.

WARNING!

On vehicles with engine with unit injectors, the temperature of the fuel lines or of the fuel can be up to 100 C in an extreme case. Let the fuel cool down before opening the lines, as other-wise there is a high risk of burning.

Wear protective gloves. Wear safety glasses.

Note

WARNING!

Refrigerant circuit of the air conditioning system must not be opened.

Note



10-1 page 3

10

Remove fan shroud and radiator Chapter 19-1. Remove the support of the allocation for the oil level/

temperature sender from the assembly carrier. Remove the drive shaft on the right and unscrew the

drive shaft on the left from the gearbox flange Chassis; Rep. Gr. 40.

The decoupling element in the front part of the exhaust pipe should not be bent by more than 10 - danger of damaging it.

Remove the exhaust pipe from the exhaust turbo-charger Chap. 26-1.

Unlatch the fuse and and unplug the front connector from the engine control unit Chapter. 23-2, open the cable guides -arrows-, remove the engine wiring harness and place down to the side.

Release all remaining plugs at engine and gearbox and lay aside the relevant lines.

To release the plug of the engine speed sender, press the plug together with a screwdriver and at the same time raise the release button with a thin wire hook.

Unclamp all connecting, cooling fluid, vacuum and air guide hoses from the engine.

Remove the gearshift mechanism from the gearbox Gearbox 02Q or 02E; Rep. Gr. 34.

Clamp off hydraulic hose to slave cylinder with hose clamp -MP 7-602-.

Pull the pressure line -1- out of the hose coupling; to do so raise the fuse of the hose coupling -arrow-.

Release screws -1...3- and remove pendulum sup-port.

WARNING!

Shut off the openings of the charge air cooler, e.g. with a clean foam piece, so that no coolant can penetrate.

Note

Note

WARNING!

After separating the hydraulic line, do not operate the clutch pedal.



10

Screw engine mount -T10012- to the cylinder block with fixing nut and bolt. Tighten bolt M10x25/8.8 to a tightening torque of approx. 40 Nm.

The pins must be screwed onto the engine mount -T10012-, as shown. The threaded bores must be posi-tioned on the gearbox side.

Insert engine/gearbox jack (e.g. -V.A.G 1383 A -) at the engine mount -T10012- and slightly raise.

Use double ladder (e. g. -VAS 5085-) to release the screws for the engine/gearbox mounting.

Successively release screws for engine mounting -ar-rows- ...

... and gearbox mounting -arrows-.

Check whether all hose and line connections between engine, gearbox and body are released.

When lowering carefully guide the engine with the gearbox, in order to avoid damage.

Carefully lower engine with gearbox. Remove the gearbox from the engine Manual

Gearbox 02Q; Rep. Gr. 34, Automatic Gearbox 02E; Rep. Gr. 34.

Securing the engine to the assembly stand


Lifting device -MP 9-201- Engine mount -MP 1-202- Extension -MP 1-202/10- Bushing -T30010-

Note

Note

Note



10-1 page 5

10

Assembly stand -MP 9-101- Workshop crane (e.g. -V.A.G 1202A-)

Procedure

Separate engine from gearbox.

Attach lifting device -MP 9-201- at engine and at work-shop crane (e.g. -V.A.G 1202A-).

On the belt pulley side: 2. Hole of the extension in Posi-tion 1

On the flywheel side: 4. Hole of the extension in Position 8

Lift off engine with installed engine mount -T10012- with workshop crane from engine/gearbox jack.

Remove engine mount -T10012-. For carrying out assembly work, attach the engine

with the engine mount -MP 1-202-, the extension -MP 1-202/10- and the sleeves -T30010 - to the as-sembly stand -MP 9-101-. (The figure shows the 1.9 ltr./47kW SDI Engine; the fixing system is identical).

Installing

Procedure

Mount engine onto engine mount -T10012-.Installation is performed in the reverse order. Pay atten-tion to the following points:

When undertaking assembly replace self-locking nuts and screws which have been tightened to a turning angle.

Always replace gasket rings and seals. All cable straps should be fitted on again in the same

place when installing. Secure all hose connections with corresponding hose

clips.

Engine with coupling for the manual gearbox 02Q

Clean the serration on the drive shaft and if the clutch discs have been used clean the hub serration, remove corrosion and only apply a very thin layer of grease

WARNING!

Use securing pins on the hooks and rig pins to prevent release.

8

MP 9-201

1 2 3 46 75

S10-0175

T30010

MP 1-202

S10-0123

Note

Note



10

-G 000 100-. Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Always remove all excess grease.

After installing the coupling, check the centering of the clutch disc Manual Gearbox 02Q; Rep. Gr. 30.

Check the clutch release bearing for wear. Replace release bearing if worn Manual Gearbox 02Q; Rep. Gr. 30.

Engine without coupling for the automatic gearbox 02E

Check needle bearing for drive shaft pin in the crank-shaft. Replace bearing if worn Chapter 13-2.

Lubricate needle bearing and drive shaft pin with a thin layer of grease -G 052 133 A2-. Do not grease the serration of the drive shaft.

Continued for all engines:

Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; in-sert if necessary.

Ensure that the intermediate plate has been inserted on the sealing flange and is pushed onto the dowel sleeves -arrows-.

Screw on gearbox to engine Gearbox 02Q or 02E;

Rep. Gr. 34. Insert engine with gearbox into the body. First screw in successively screws for bearing at en-

gine -arrows- ...

... and at gearbox -arrows- by hand. Use new screws for attaching.

Tighten screws to a final torque only when adjusting the engine and gearbox mounting.

Note

Note



10-1 page 7

10

Remove engine mount -T10012- from engine. Tighten pendulum support with screws -1...3- at gear-

box and at assembly carrier. Use new screws for at-taching.

Replace the O-ring -1- on the right rigid shaft and grease the serration -2- with universal grease.

Install the right drive shaft and screw the left drive shaft onto the gearbox flange Chassis; Rep. Gr. 40.

Install exhaust system and align free of stress Chapter 26-1.

Connect hydraulic line to cylinder of hydraulic clutch control and bleed clutch hydraulic Manual Gearbox 02Q; Rep. Gr. 30.

Attach shift mechanism to gearbox and adjust Gearbox 02Q or 02E; Rep. Gr. 34.

Install fan shroud and radiator Chapter 19-1.On vehicles with air conditioning:

Installing AC compressor and holder for auxiliary units Chapter 13-1.

Continued for all vehicles

Install alternator Electrical System; Rep. Gr. 27. Install the V-ribbed belt Chapter 13-1. Connect all connecting, fuel, cooling fluid, oil, vacuum

and suction hoses to the engine. When installing the air guide pipe with push-fit coupling ensure that the locking clip -arrow- interlocks behind the retaining lug -A-.

Adjust assembly bracket 10-1 page 8. Connect electrical connections and attach cables Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.

Install battery Electrical System; Rep. Gr. 27 Install intermediate wall and cover of the plenum

chamber Body Work; Rep. Gr. 66. Install wiper arms Electrical System; Rep. Gr. 92. Install the middle sound dampening system Body

Work; Rep. Gr. 50. Top up coolant Chapter 19-1.



10

Inspect oil level Inspection and Maintenance.

Tightening torques

Adjust assembly bracket


Supporting device -T30099- Hook of -MP 9-200-The following distances must be achieved:

Between engine support and frame side rail on right there must be a distance -a- = 13.5 mm.

The cast iron edge on the engine support -2- must be parallel to the supporting arm -1- (dimension -x- = di-mension -x-).

The distance -a- = 13.5 mm can be checked e.g. with suit-able round bars.

Assembly bracketTightening torques

Fig. 1: Engine assembly bracket

A - 20 Nm + 90 (1/4 turn) - replaceB - 40 Nm + 90 (1/4 turn) - replaceC - 60 Nm + 90 (1/4 turn) - replaceFig. 2: Gearbox assembly bracket

1 - 40 Nm + 90 (1/4 turn) - replace2 - 60 Nm + 90 (1/4 turn) - replace

Component NmScrews and nuts M6 9

M7 13M8 20

M10 40M12 70

Engine/gearbox connecting screws Gearbox 02Q or 02E; Rep. Gr. 34

Note



10-1 page 9

10

Fig. 3: Hinged bracket

A - 40 Nm + 90 (1/4 turn) - replaceB - 100 Nm + 90 (1/4 turn) - replace



10


Disassembling and assembling engineEdition 01.05S00.5709.01.20

13-1 page 1

13

13-1 Disassembling and assembling engine

Removing and installing V-ribbed belt

1 - Belt pulleyT with vibration damperT can be installed only in one

position2 - CapT for belt pulley

3 - 10 Nm + torque a further 90 (1/4 turn)T replace

4 - Tensioning device for ribbed V-beltT swivel tensioning device for

V-ribbed belt with open-end wrench to slacken the V-ribbed belt

T can be interlocked with locat-ing bolts -T10060- or -T10060A-, or Allen key.

5 - 23 Nm6 - 40 Nm + torque a further 90

(1/4 turn)T replace

7 - Large guide pulleyT for toothed belt

8 - Bracket for auxiliary unitsT order of tightening Fig. 1

in 13-1 page 29 - Bushing

10 - AC generatorT removing and installing Electrical System; Rep. Gr. 27

T to facilitate positioning, drive the threaded bushings of the retaining screws at the generator slightly back-wards

11 - 45 NmT insert using locking agent -D 000 600 A2-T observe the order of tightening up Fig. 1 in 13-1 page 2

12 - BushingT 2 piecesT must be inserted into the support item 8

13 - 25 Nm14 - AC compressor15 - V-ribbed belt

T mark the direction of rotation with chalk or a felt-tip pen before removingT check for wearT do not kinkT removing 13-1 page 2

13 Crankgear


Disassembling and assembling engine Edition 01.05S00.5709.01.2013-1 page 2

13

T installing 13-1 page 3

Fig. 1: Bolts at bracket for auxiliary units - tighten-ing sequence

Removing

Removing engine cover Chapter 10-1. Unlatch fuses, remove fuel filter with its connected

lines upwards from bracket -arrow- and lay to the side.

Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.

Note



13-1 page 3

13

Swing the the tensioning device in -the direction of the arrow- detension the V-ribbed belt.

Hold the tensioning device and remove the slackened V-ribbed belt.

InstallingInstallation is performed in the reverse order. Pay atten-tion to the following points:

Before fitting the ribbed V-belt make sure that all assem-blies (generator and AC compressor) are securely mounted.

First position the ribbed V-belt on the belt pulleys of the crankshaft and AC compressor and on the belt pulley of the generator last; then release the tension-ing device.

Check correct positioning of the ribbed V-belt on the belt pulleys.

Start engine and check ribbed V-belt run.

Note



13

Removing and installing timing belt

Summary of components - part 1

1 - CoverT for belt pulley


3 - V-ribbed belt pulleyT with vibration damperT can be installed only in one

position4 - 10 NmT insert using locking agent

-D 000 600 A2-5 - 40 Nm + torque a further 90

(1/4 turn)T replaceT observe the order of tighten-

ing up Fig. 2 in 13-1 page 4

6 - Engine support bracket7 - Top toothed belt guardT when installing, correctly in-

sert into the middle toothed belt guard

8 - Middle toothed belt guardT to remove, remove top

toothed belt guard and un-screw tensioning device for ribbed V-belt.

9 - Bottom toothed belt guard

Fig. 2: Tightening order for engine support

Screw in screws -13- by hand first. Tighten screws -13- and 40 + torque a further 90 (1/

4 turn).

Summary of components - part 2

Mark the direction of rotation with chalk or a felt-tip pen before removing the toothed belt. Reversing the rotation direction of an already used belt may destroy it.

Note



13-1 page 5

13

1 - 120 Nm + torque a further 90 (1/4 turn)T replaceT do not lubricateT to release and tighten use

counterholder -T30004 - or counterholder -MP 1-310-

2 - 20 Nm3 - Small guide pulley4 - 20 Nm + torque a further + 45

(1/8 turn)5 - Tensioning pulleyT The eccentric of the new ver-

sion has an additional hole for 6 mm hexagon socket wrench Fig. 3 in 13-1 page 6

6 - Timing beltT mark the direction of rotation

with chalk or a felt-tip pen be-fore removing

T check for wearT do not kinkT removing 13-1 page 6T install (set the timing) 13-1 page 9

7 - Camshaft sprocketT for exhaust camshaftT Check fitting position

8 - Camshaft sprocketT for inlet camshaftT Check fitting position

9 - 100 NmT to release and tighten use counterholder -T10051 -

10 - HubT for exhaust camshaftT to remove use extractor -T10052-

11 - HubT for inlet camshaft with rotor for hall sender -G40-T to remove use extractor -T10052-

12 - Rear timing belt guard13 - Feed-through

T replace if damaged14 - 10 Nm

T insert using locking agent -D 000 600 A2-15 - O-ring

T replace16 - Coolant pump

T removing and installing Chapter 19-117 - 13 Nm18 - Toothed belt gear

T for toothed belt on the crankshaftT there must not be any oil present on contact surface between timing belt sprocket and the crankshaftT can be installed only in one position



13

19 - Large guide pulley20 - 40 Nm + torque a further 90 (1/4 turn)

T replace

Fig. 3: Tensioning pulley

Additional hole in the eccentric of the tensioning pulley for 6 hexagon socket wrench -arrow-.

The tensioning pulley of the new version can be adjusted with the special two-hole nut turner , e. g. -T10020-, or us-ing a commercial 6 mm hexagon socket wrench.

Removing


Supporting device -T30099- Hook of -MP 9-200- Rig pin -3359- or -MP 1-301 - (2x) Pliers for spring strap clips Two-hole nut turner -T10020- Crankshaft arrester -T10050- or -T10100- Locating bolts -T10060- or -T10060A - Counterholder -T10172- with bolts -T10172/4- Torque wrench Remove V-ribbed belt 13-1 page 1. Remove the right sound dampening system Body

Work; Rep. Gr. 50. Unscrew air guide pipe and remove V-ribbed belt pul-

ley with vibration damper.

Disconnect the fuel-intake hoses and the fuel-return hoses from the fuel pipes on the body as well as at the engine and pull fuel filter with its attached hoses to the top out of the bracket -arrow-.

Note

WARNING!

On vehicles with engine with unit injectors, the temperature of the fuel lines or of the fuel can be up to 100 C in an extreme case. Let the fuel cool down before opening the lines, as other-wise there is a high risk of burning.

Wear protective gloves. Wear safety glasses.



13-1 page 7

13

Unbolt bracket -3- for fuel filter. Unscrew bolt on filler neck -2- of windscreen washer

reservoir. Unscrew the coolant expansion bottle -1- and lay with

connected lines to one side.

Remove top toothed belt guard, to do so release re-taining clips -arrows-.

Remove ribbed V-belt tensioning device. Remove middle and bottom timing belt guard. Position the supporting device -T30099- on the body,

suspend the engine on the right lifting eye with hook of -MP 9-200- and preload via the spindle, however do not lift.

Release screws -1- and -2- and remove connecting stud.

Release screws -3...6- and remove engine console.



13

Release screws -1...3- for engine support and remove support.

To slacken the bolts for the engine support, raise engine slightly via spindle of supporting device -T30099-.

Rotate crankshaft to TDC of cylinder 1.

In the TDC position, both tooth segments of the camshaft sprockets -arrows- point upwards.

Lock hubs with locking pins -3359-. Depending on the version, lock the crankshaft timing

belt sprocket with the crankshaft arrester -T10050- or crankshaft arrester -T10100-.

Version of the crankshaft timing belt sprocket:

A = original version of timing belt sprocket with circular tooth flank, rectangular marking for TDC at tooth in 12 o'clock - use crankshaft arrester -T10050-

B = new version of timing belt sprocket with eliptical tooth flank, triangular marking for TDC at tooth opening 1 o'clock - use crankshaft arrester -T10100-

The markings on the timing belt gear and on the crankshaft arrester must be in line with each other -ar-row-. The stud on the crankshaft arrester must en-gage into the hole in the sealing flange.

The crankshaft arrester can only be fitted onto the tim-ing belt gear from the front side of the serration.

Note

WARNING!

Turn the engine only with the crankshaft in the run-ning direction of the engine (from the side of the crankshaft toothed belt sprocket clockwise).

Note

Note



13-1 page 9

13

Mark the direction of rotation of the timing belt with chalk or a felt-tip pen.

Loosen bolts of camshaft sprocket -arrows- by about 2 turns.

Counterhold eccentric of tensioning pulley with two-hole nut turner (e.g. -T10020-) and loosen the fixing nut -1-. After this, release the tensioning pulley by turning the eccentric anti-clockwise, until spring ten-sion releases. Secure the loose tensioning pulley by tightening the fixing nut by hand.

Remove small toothed belt guide pulley item 3 in 13-1 page 5.

First of all take toothed belt off toothed belt sprocket of coolant pump and then from the other belt pulleys.

Installing (set the timing)

Camshafts are interlocked with locking pins -3359-. Crankshaft is is locked with crankshaft arrester

-T10050- or crankshaft arrester -T10100-. Interlock tensioning pulley in released position with

fixing nut.

Always perform adjusting work on the timing belt only on a cold engine.

When rotating the camshafts, the crankshaft must not be positioned at TDC for any one piston. Risk of dam-aging valves and pistons.

Pay attention to the correct fitting of the tensioning pulley in the opening in the rear timing belt guard -ar-row-.

A13-0675

Note



13

Slightly screw in screws -arrows-.

It must still be possible to turn the camshaft sprockets on the hubs, however they must not hang loose.

Turn camshaft sprockets clockwise in the elongated holes as far as the stop.

Fit toothed belt onto crankshaft toothed belt sprocket, tensioning pulley, camshaft sprockets, large guide pulley and, last of all, onto the toothed belt sprocket of the coolant pump.

Install small toothed belt guide pulley item 3 in 13-1 page 5.

Loosen the fixing nut -1- of the tensioning pulley. Turn the eccentric of the tensioning pulley with two-

hole nut turner (e. g. -T10020-) clockwise in such a way until the pointer -2- stands in the centre of the base plate in the gap.

Ensure that the fixing nut does not turn.

Hold the eccentric of the tensioning pulley in this posi-tion and tighten fixing nut of tensioning pulley to 20 Nm + torque a further 45 (1/8 turn).

When tightening the fixing nut, the pointer turns -arrow- max. 5 mm to the right from the gap of the base plate. This position must not be corrected, because the toothed belt settles when running-in.

Note

Note



13-1 page 11

13

Insert counterholder -T10172- with bolts -T10172/4- as shown and press in -direction of arrow-.

Keep camshaft sprockets with counterholder -T10172 - under tension and tighten screws -arrows- of both camshafts to 20 Nm + torque a further 45 (1/8 turn).

Remove locking pins -3359- and crankshaft arrester -T10050- or crankshaft arrester -T10100 -.

Test timing:

Turn crankshaft 2 turns in the direction of running of the engine until the crankshaft is positioned shortly before TDC for cylinder 1.

Interlock during this motion the hub -A- in the direction of running of the engine with locking pin -3359-.

Check whether: the hub -B- can be interlocked with the locating pin

-3359-; the crankshaft can be interlocked with the crankshaft

arrester -T10050 - or crankshaft arrester -T10100- The pointer of tensioning pulley stands in the centre or

max. 5 mm to the right from the gap of the base plate.

If the hub -B- cannot be arrested:

Loosen fixing bolts -2- of the camshaft timing gear for inlet camshaft -B-.

Fit ring spanner onto the central screw of the inlet camshaft.

Turn the hub until the locking pin -3359- can be insert-ed.

Tighten bolts -2- of camshaft sprocket for inlet cam-shaft -B- to 20 Nm and torque a further + 45 (1/8 turn).


Turn crankshaft 2 turns in the direction of running of the engine until the crankshaft is positioned in the TDC for cylinder 1.

Repeat timing test 13-1 page 11.If the crankshaft cannot be arrested:



13

Loosen bolts -1- and -2- of camshaft sprockets -A- and -B-.

Rotate crankshaft in direction of rotation of engine un-til it can be arrested with the crankshaft arrester -T10050- or crankshaft arrester -T10100-.

If the crankshaft can be turned behind the TDC for cylin-der 1, turn crankshaft back slightly and once again set to the TDC for cylinder 1 by turning in direction of rotation of engine.

Insert counterholder -T10172- with bolts -T10172/4- as shown and press in -direction of arrow-.

Keep camshaft sprockets with counterholder -T10172 - under tension and tighten screws -1- und -2- of the camshaft sprockets -A- and -B- to 20 Nm + torque a further 45 1/8 turn).


Turn crankshaft 2 turns in the direction of running of the engine until the crankshaft is positioned in the TDC for cylinder 1.

Repeat timing test 13-1 page 11.Proceed with installation:

Further installation occurs in reverse order for removal, while paying attention to the following:

Replace gaskets. Secure all hose connections with corresponding hose

clips.

Install bottom and middle toothed belt guard. Screw on engine support Fig. 2 in 13-1 page 4, in-

stall and adjust engine mounting Chap. 10-1.

Note

Note



13-1 page 13

13

The engine support must be tightened up firmly before further installation of the right engine mounting.

Install belt pulley and tensioning device for V-ribbed belt.

Install the V-ribbed belt 13-1 page 1. Install top toothed belt guard. Install charge air pipes and charge air hoses Chap.

21-2. Install the front right wheelhouse liner Body Work;

Rep. Gr. 66. Install fuel filter and coolant expansion reservoir.

Note



13


Removing and installing sealing flanges and flywheelEdition 01.05S00.5709.01.20

13-2 page 1

13

13-2 Removing and installing sealing flanges and fly-wheel

Repairing the clutch Manual Gearbox 02Q; Rep. Gr. 30.

1 - Gasket ringT replace 13-2 page 2T Neither oil nor grease

2 - Front sealing flangeT must be positioned on dowel

sleevesT removing and installing 13-2 page 4

T install with silicone sealant -D 176 404 A2-

3 - Cylinder blockT with fitted crankshaftT Replace needle bearing for

crankshaft 13-2 page 144 - The two-mass flywheelT removing and installing 13-2 page 13

T Assembly is only possible in one position through offset holes.


6 - Intermediate plateT must be positioned on dowel

sleevesT do not damage/bend during

assembly workT inserted on sealing flange Fig. 1 in 13-2 page 2

7 - 15 NmT replace

8 - Rear sealing flangeT Always replace complete with gasket ring and if possible with rotor of engine speed sender -G28-T replace 13-2 page 5

9 - Engine speed sender -G28-10 - 5 Nm

Note


Removing and installing sealing flanges and flywheel Edition 01.05S00.5709.01.2013-2 page 2

13

Fig. 1: Installing intermediate plate

Insert intermediate plate on sealing flange and push onto the dowel sleeves -arrows-.

Replacing gasket ring for crankshaft -on the belt pulley side-


Counterholder -T30004- or counterholder for timing belt sprocket -MP 1-310-

Gasket ring extractor -MP 1-226- Assembly device -T10053- Torque wrench

Removing

Engine installed. Remove the V-ribbed belt Chapter 13-1. Remove the timing belt Chapter 13-1. Remove crankshaft timing belt sprocket, to this end

lock the timing belt sprocket with counterholder or counterholder for timing belt sprocket.

Before inserting the gasket ring extractor, screw the central bolt of the timing belt sprocket into the crank-shaft by hand up to the stop.

T 30004

MP 1-310

S13-0166



13-2 page 3

13

Turn inner part of gasket ring extractor -MP 1-226- two turns (approx. 3 mm) out of the outer part and lock with knurled screw.

Oil the thread head of the gasket ring extractor, posi-tion and forcely screw into the gasket ring as far as possible.

Release knurled screw and turn the inner side against the crankshaft until the gasket ring is pulled out.

Clamp gasket ring extractor into the vice and remove gasket ring with pliers.

Clean the contact and sealing surface.

Installing

Do not oil the sealing lip and the outer surface of the gas-ket before the pressing in procedure.

Remove oil residue on the crankshaft stub with a clean cloth.

Insert guide bushing -T10053/1- on the crankshaft stub.

Slide gasket ring over the guide bushing.

Press in the gasket ring flush with the central screw for toothed belt sprocket and with pressure bushing of -T10053-.

There must not be any oil present on contact surface between timing belt sprocket and crankshaft.

Replace central screw for crankshaft toothed belt gear.

Do not oil the central screw for the timing belt sprocket crankshaft.

Install crankshaft timing belt sprocket, to this end lock the timing belt sprocket with counterholder.

Install the timing belt (set the timing) Chapter 13-1. Install the V-ribbed belt Chapter 13-1.

MP 1-226 S13-0078

Note

Note



13

Removing and installing the front seal-ing flange


Counterholder -T30004- or counterholder for timing belt sprocket -MP 1-310-

Assembly device -T10053- Torque wrench Flat scraper Hand-held power drill with plastic brush insert Protective goggles Silicone sealant -D176 404 A2-

Removing

Engine installed. Remove the V-ribbed belt Chapter 13-1 Remove the timing belt Chapter 13-1 Remove crankshaft timing belt sprocket, to this end

lock the timing belt sprocket with counterholder or counterholder for timing belt sprocket.

Drain engine oil Inspection and Maintenance. Removing oil pan Chapter 17-1. Unscrew the fixing screws of the front sealing flange

and remove sealing flange, if necessary release by applying slight blows with a rubber-headed hammer.


Carefully remove the remaining sealant on the cylin-der block.

Remove the remaining sealant on the sealing flange and on the oil pan using a device such as a rotating plastic brush.

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

Pay attention to the 'use by date' on the silicone sealant.

T 30004

MP 1-310

S13-0166WARNING!

Wear safety glasses.

Note



13-2 page 5

13

Cut off nozzle tube at the front marking ( of nozzle approx. 3 mm).

Apply silicone sealant bead -arrow- to the clean seal-ing surface of the upper part of the sealing flange, as shown.

Thickness of sealant bead -arrow-: 2 ... 3 mm.

The sealant bead must not be thicker than 3 mm oth-erwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.

The sealing flange must be installed within 5 minutes after applying the silicone sealant.

When installing the sealing flange with the gasket ring fitted place a guide sleeve -T10053/1- on the crank-shaft journal.

Carefully push the sealing flange onto the dowel sleeves at the cylinder block and tighten new fixing bolts by hand.

Tighten the screws of the sealing flange alternately and crosswise.

Installing oil pan Chapter 17-1. Install crankshaft timing belt sprocket, to this end lock

the timing belt sprocket with counterholder or counter-holder for timing belt sprocket.

Install the timing belt (set the timing) Chapter 13-1. Install the V-ribbed belt Chapter 13-1. Fill with engine oil and check the oil level Inspection

and Maintenance.

Replace rear sealing flange


Assembly device -T10134- Depth gauge Screw M6x35 (3x) Screw M7x35 (2x) Torque wrench

Removing

Gearbox removed. Remove the two-mass flywheel 13-2 page 13. Remove the intermediate plate from the dowel

sleeves and unhook from sealing flange -arrows-. Position engine to TDC of cylinder 1 Chapter 13-1.

Note



13

Remove engine speed sender -G28- -position 1-. Removing oil pan Chapter 17-1. Release the fixing screws of the rear sealing flange.

Sealing flange and rotor are pressed together with three M6 x 35 mm screws from the crankshaft.

To this end screw 3 screws M6 x 35 alternately by max. 1/2 turn into the sealing flange.

Remove gasket ring together with rotor.

Installing

The sealing flange with PTFE gasket ring is provided with sealing lip supporting ring. This supporting ring is intended as an assembly sleeve and must not be re-moved before installing.

Do not separate or turn the sealing flange and rotor af-ter removing them from the spare part package.

The rotor is given its fitting location by fixing the as-sembly device -T10134- to the positioning pin.

The sealing flange and gasket ring form one unit and must be replaced together with the rotor.

The assembly device -T10134- is given its fitting loca-tion to the crankshaft by means of a guide bolt, which is guided into a hole of the crankshaft.

Assembly device -T10134-

A - Clamping surfaceB - Hexagon nutC - Assembly cupD - Positioning pinE - Allen screwF - Guide bolt for diesel engines (red handle)G - Guide bolt for petrol engines (black handle)

A - Mounting the sealing flange with gasket ring and rotor on the assembly device -T10134-:

Screw the hexagon nut -B- right up to the clamping surface -A- of the threaded spindle.

Note

Note



13-2 page 7

13

Grip assembly device assembly device -T10134- on clamping surfaces -A- of the threaded spindle in a vice.

Push assembly cup -C- down so that it rests on the hexagon nut -B- -arrow-

The inner part of the assembly device and assembly cup must be at the same level.

Remove the securing clip -arrow- from the new seal-ing flange.

Do not remove or turn the rotor from the sealing flange.

The locating hole -A- on the rotor -C- must be flush with the marking -B- on the sealing flange.

Note

Note



13

Lay the front side of the sealing flange on a clean and level surface.

Press down sealing lips supporting ring -A- in -direc-tion of the arrow-, until it rests on the level surface.

The top side of the rotor and the front side of the seal-ing flange must be flush -arrows-.

Lay the sealing flange with the front side on theas-sembly device -T10134- in such a way that the posi-tioning pin -B- engages in the hole -A- of the rotor.

Make sure the sealing flange lies flat on the assembly de-vice.

Note



13-2 page 9

13

When tightening the three knurled screws -A- press the sealing flange and sealing lip supporting ring -B- on the surface of the assembly device -T10134- in such a way that the positioning pin cannot slide out of the rotor hole.

Make sure the rotor remains fixed in the assembly device while mounting the sealing flange.

B - Mounting the assembly device -T10134- with seal-ing flange on the crankshaft flange

The crankshaft flange must be free of grease and oil. The engine is at TDC for cylinder 1

Screw in hexagon nut -B- up to the end of the thread-ed spindle.

Press the threaded spindle of the assembly device -T10134 - in -direction of the arrow- until the hexagon nut -B- rests on the assembly cup.

Align the flattened side of the assembly cup with the cylinder block on the oil pan side.

Attach assembly device -T10134- to the crankshaft flange, to this end screw in Allan screws -A- with ap-proximately 5 thread turns onto the crankshaft flange.

Note



13

Screw 2 screws M7 x 35 -A- for guide of sealing flange into the cylinder block.

C - Screwing the assembly device -T10134- onto the crankshaft flange:

Push the assembly cup -A- by hand in the -direction of the arrow- until the sealing lips supporting ring -B- rests on the crankshaft flange -A-.

Push guide bolt for diesel engines (red handle) -D- into the hole of the crankshaft. This gives the rotor its final fitting location.

The guide bolt for petrol engines (black handle) -F- must not be fitted into the threaded hole of the crankshaft.

Tighten the 2 Allan screws of the assembly device by hand.

Screw in hexagon nut -E- by hand onto the threaded spindle until it rests against the assembly cup -C-.

D - Pressing the rotor with assembly device - T10134- onto the crankshaft flange

Tighten the hexagon nut of the assembly device -T10134 - to 35 Nm.

After tightening the hexagon nut to 35 mm there must still be a narrow air gap between the cylinder block and the sealing flange.

Note

Note



13-2 page 11

13

E - Inspecting the fitting position of the rotor on the crankshaft:

Screw in hexagon nut -E- up to the end of the thread-ed spindle.

Release 2 screws -A- from the cylinder block. Release the 3 knurled screws -B- from the sealing

flange. Remove assembly device -T10134-. Remove sealing lips supporting ring.

The fitting position of the rotor on the crankshaft is ac-curate if there is a distance -a- of 0.5 mm between the crankshaft flange -A- and the rotor -B-.

Position the caliper gauge onto the crankshaft flange. Measure distance -a- between crankshaft flange and

rotor.

If the dimension -a- is too small:

Press down rotor 13-2 page 12.If the dimension -a- is correct:

Proceed with installation 13-2 page 13.



13

F - Pressing down the rotor:

Attach assembly device -T10134- -A- to crankshaft flange, to do so tighten the Allen screws by hand.

Slide assembly device -T10134- by hand towards the sealing flange.

Screw in hexagon nut -E- by hand onto the threaded spindle until it rests against the assembly cup -C-.


Again inspect the fitting position of the rotor on the crankshaft 13-2 page 11.

If the dimension -a- is again too small:


Again inspect the fitting position of the rotor on the crankshaft 13-2 page 11.



13-2 page 13

13

complete installation:

Tighten the new fixing screws of the sealing flange crosswise.

Screw on engine speed sender -G28- -position 1-. Installing oil pan Chapter 17-1. Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-. Install the two-mass flywheel 13-2 page 13.

Removing and installing the two-mass flywheel


Flywheel lock -MP 1-504-.

Removing

Secure two-mass flywheel by inserting the flywheel lock -MP 1-504- into the serration and turn sufficiently until it touches the bushing -T30010-.

Mark installation position of two-mass flywheel on crankshaft.

MP 1-504S13-0191

T30010T30010

MP 1-202



13

To avoid destroying the two-mass flywheel during remov-al, the screws -B- must not be unscrewed with a com-pressed air or an impact screwdriver. They must only be unscrewed by hand. Ensure that no screw head touches the two-mass flywheel, otherwise the flywheel may be damaged at the following turning of the screw.

Rotate two-mass flywheel -A- in such a way that the screws are positioned in the middle of the holes -ar-rows-.

Screw out the screws.


Use new screws for attaching. Install the flywheel in the location marked when re-

moving.

Replace needle bearing for crankshaft


Centering mandrel -T30029- Special tool Kukko 21/21 (or 21/2) and Kukko 22/1 Pull out needle bearing with interior extractor

-Kukko 21/1 (oder 21/2)- and support -Kukko 22/1-

The side with the marking on the needle bearing must point outwards after driving in.

Carefully insert new needle bearing with centering mandrel - T30029- into the crankshaft.

Note

Note

Note


Crankshaft, Piston and ConrodEdition 02.04S00.5709.00.20

13-3 page 1

13

13-3 Crankshaft, Piston and Conrod

Removing and installing crankshaft

The engine should be attached to the engine repair stand with the engine holder -MP 1-202- for carrying out remov-al and installation work.


2 - Bearing capsT Bearing cap 1: on the belt

pulley sideT bearing cap 3 with recesses

for thrust washersT retaining lugs of the bearing

shells of the cylinder block/bearing cap must be on top of one another

3 - Bearing shell 3T for cylinder block with lubri-

cating grooveT for bearing cap without lubri-

cating grooveT do not mix up used bearing

shells (mark)4 - Thrust washersT for bearing cap 3T different version for cylinder

block and bearing capT pay attention to locating ele-

ment5 - CrankshaftT with chain sprocket for oil

pump driveT Axial play when new: 0.07...

0.17 mm, wear limit: 0.37 mm

T Crankshaft bearing journal: 54.00 mm

T Conrod bearing journal: 50.90 mm6 - Bearing shells 1, 2, 4 and 5T for cylinder block with lubricating grooveT for bearing cap without lubricating grooveT do not mix up used bearing shells (mark)

Note


Crankshaft, Piston and Conrod Edition 02.04S00.5709.00.2013-3 page 2

13

Disassembling and assembling piston and conrod

1 - Piston ringsT Offset joint 120T use piston ring pliers for re-

moving and installingT marking TOP must face to-

wards piston crownT inspect gap clearance Fig. 1 in 13-3 page 3

T inspect end clearance Fig. 2 in 13-3 page 3

2 - PistonT with combustion chamberT mark installation position and

matching cylinderT Installation position and as-

signment of piston/cylinder Fig. 4 in 13-3 page 4

T arrow on piston crown faces towards the belt pulley side

T replace piston if there is any sign of crack formation on the piston body

T Inspecting pistons Fig. 3 in 13-3 page 3

T Piston dimenston: 80.96 mm

T use piston ring tensioning strap for installing

T inspect piston projection at TDC 13-3 page 4

3 - Piston pinT if stiff, heat piston to approx.

60CT use drift -MP 3-400- for removing and installing

4 - Circlip5 - ConrodT always replace as a set onlyT mark matching cylinder -A-T Fitting position: Markings -B- point towards the belt pulley sideT with a split bearing cap

6 - Bearing shellT Fitting position Fig. 6 in 13-3 page 4T do not mix up used bearing shells (mark)T Pay attention to version: top bearing shell (towards the piston) must be made from a long lasting material,

recognition feature for new bearing shells: black marking on the contact surface near the separation pointT insert in middle Fig. 6 in 13-3 page 4T check for firm seatingT axial play wear limit: 0.37 mm

7 - Cylinder blockT Inspect cylinder Fig. 5 in 13-3 page 4T Cylinder dimension: 81.01 mm

8 - Conrod bearing capT Check fitting positionT cracked cover fits only in one position at the relevant conrod.



13-3 page 3

13

9 - Oil injection nozzleT for cooling pistons

10 - 25 NmT replace without sealant

11 - Conrod bolt - 30 Nm + torque a further + 90 (1/4 turn)T replaceT oil thread and head contact surface

Fig. 1: Inspecting piston ring gap clearance


Feeler gauge Insert ring at right angles from above down into lower

cylinder opening, about 15 mm away from edge of cyl-inder. To insert use piston without rings.

Fig. 2: Inspect piston ring end clearance


Feeler gauge Clean before inspecting the annular grooves of the

piston.

Fig. 3: Inspecting pistons


External micrometer Measure about 10 mm from the lower edge, offset at

right angles to the piston pin shaft.

Max. deviation from specified dimension: 0.04 mm.

Piston ring (dimensions in mm)

new Wear limit

1. Compression ring

0.25 0.40 1.00

2. Compression ring

0.25 0.40 1.00

Oil scraper ring 0.25 0.50 1.00

V13 - 0687

Piston ring (dimensions in mm)

new Wear limit

1. Compression ring

0.06 0.09 0.25

2. Compression ring

0.05 0.08 0.25

Oil scraper ring 0.03 0.06 0.15



13

Fig. 4: Installation position and assignment of pis-ton/cylinder

Pistons in cylinders 1...4:

arrow on piston crown faces towards the belt pulley side -arrows-.

Fig. 5: Inspecting cylinder bore


Internal precision measuring instrument Measure at 3 points crosswise in a transverse direc-

tion -A- and lengthwise -B-.

Max. deviation from specified dimension: 0.10 mm.

Fig. 6: Fitting position of the bearing shells in the conrods

Insert bearing shell in the conrod or in the center of the conrod bearing cap.

Dimension -a- = 2.5 mm

Checking piston projection in TDC


Measuring tool for piston projection -MP 1-107-



13-3 page 5

13

Test sequenceWhen fitting new pistons or a partial engine, check the piston projection in TDC on all pistons.

Depending on the piston projection fit the relevant cylin-der head seal in accordance with the table below.

Cylinder head gasket identification Spare parts No. = -arrow 1- Control code = -arrow 2- (ignore) Bores = -arrow 3-

If different values are measured during the projection measurement of the piston, the greatest dimension ap-plies for the seal assignment.

Piston projection over cylinder block - top side

mm

Bore marking

0.91 1.00 11.01 1.10 21.11 1.20 3

Note



13


Removing and installing cylinder headEdition 01.05S00.5709.01.20

15-1 page 1

15

15-1 Removing and installing cylinder head

Cylinder heads with cracks between the valve seats may continue to be used without any reduction in the life time provided the cracks are slight and max. 0.5 mm wide.

It is not permissible to rework the cylinder heads of diesel engines.

Replace O-rings and gasket rings. Replace cylinder head bolts and screws which have

been tightened to a turning angle. When installing an exchange cylinder head with the

camshaft installed, it is necessary to oil the contact surfaces between the valve levers and the cams after installing the cylinder head.

Do not remove the plastic bases supplied as a protec-tion for the open valves until just before fitting on the cylinder head.

If the cylinder head is replaced, replace all the coolant Chapter 19-1.

Change dirty engine oil Inspection and Mainte-nance.

15 Cylinder Head, Valve Gear

Note


Removing and installing cylinder head Edition 01.05S00.5709.01.2015-1 page 2

15

Summary of components

1 - Rear timing belt guard2 - Rubber feed-throughT replace if damaged

3 - Pin screw - 15 Nm4 - HubT for inlet camshaft with rotor

for hall sender -G40-T to remove use extractor

-T10052- 5 - 100 NmT to release and tighten use

counterholder -T10051 -6 - HubT for exhaust camshaftT to remove use extractor

-T10052-7 - 10 NmT insert using locking agent

-D 000 600 A2-8 - Valve-lever shaftT Mark the installation position

of the valve leverT do not interchangeT removing and installing 15-1 page 5

T Before inserting, check whether all the ball studs and O-rings are inserted in the unit injectors.

9 - 20 Nm + torque a further 90 (1/4 turn)T pay attention to order for

slackening 15-1 page 6T pay attention to order and procedure for tightening 15-1 page 9

10 - Gasket for cylinder head coverT replace if damaged or leakingT press onto the spacer sleeves item 15

11 - Cylinder head coverT removing and installing 15-1 page 3

12 - Cap13 - Gasket

T replace if damaged or leaking14 - Sealing sleeve15 - 10 Nm

T pay attention to sequence for loosening and tightening 15-1 page 316 - 20 Nm17 - Cylinder head bolt

T replaceT pay attention to order for slackening 15-1 page 6T pay attention to order and procedure for tightening 15-1 page 10

18 - 20 Nm19 - Tandem pump

T removing and installing Chapter 20-1



15-1 page 3

15

20 - GasketT replace

21 - Cylinder headT removing 15-1 page 6T check for distortion Fig. 1 in 15-1 page 3T installing 15-1 page 9T after replacing, replace all the coolant Chapter 19-1

22 - Cylinder head gasketT replace 15-1 page 6T Pay attention to the marking Fig. 2 in 15-1 page 3

23 - Hall sender -G40-T for camshaft position

Fig. 1: Inspecting the cylinder head for distortion

Inspect cylinder head at several points for distortion using a knife-edge straightedge and feeler gauge.

Max. permissible distortion: 0.1 mm.

It is not permissible to rework the cylinder heads of diesel engines.

Fig. 2: Cylinder head gasket identification

Spare parts No. = -arrow 1- Control code = -arrow 2- (ignore) Bores = -arrow 3-

Differing thicknesses of cylinder head gaskets are insert-ed according to the piston projection. If only the gasket is replaced, then it must be replaced with a new gasket with the same marking.

removing and installing cylinder head cover


Torque wrench

Note

Note



15

Removing

Removing engine cover Chapter 10-1. Detach the air guide hose -3-.

Unscrew screws -1- and -2- and slacken bracket -3- for fuel hoses on the left engine lifting eye.

Coolant hoses as well as fuel lines remain connected.

Remove top toothed belt guard, to do so release re-taining clips -arrows-.

Note



15-1 page 5

15

Release screws -1- and -3-. Remove crankcase ventilation hose -2- from air guide

to turbocharger and press the air guide to the rear.

Air guide pipe -Position 4- remains connected to the turbocharger.

In the fig., the illustration is shown from the rear with the engine removed.

Release the cylinder head bolts in the order -11...1-. Release screws and remove cylinder head cover with

gasket.


Replace gasket for cylinder head cover and bolts of cylin-der head cover if damaged.

First tighten the cylinder head bolts in the order -1...11-, then to 10 Nm.

Removing and installing cylinder head


Supporting device -T30099- Hook of -MP 9-200- (with spindle) Bracket -T10014- Catch pan (e.g. -V.A.G 1306-) Pliers for spring strap clips Pressure pad -T10051- Extractor -T10052- Rig pin -3359- or -MP 1-301 - (2x) Two-hole nut turner -T10020- Crankshaft arrester -T10050- or crankshaft arrester

-T10100- Locating bolts -T10060- or -T10060A -

Note

Note



15

Removing

Disconnect the earth strap from the battery with the ig-nition off.

Removing engine cover Chapter 10-1. Remove air filter, charge air pipes and charge air hos-

es Chap. 21-2. Remove the middle sound dampening system Body Work; Rep. Gr. 50.

Position drip tray (e.g. -V.A.G 1306-) under the en-gine.

Drain coolant Chapter 19-1. Remove fuel feed line -3- and fuel feed line -2-, to do

so pull latch clips. Use hand vacuum pump to extract the fuel at the re-

turn-flow hose of the tandem pump Chap. 20-1.

Detach fuel filter with its connected hoses upwards from the bracket -arrow- and lay to the side.

Remove the V-ribbed belt Chapter 13-1. Unscrew the right air guide pipe between the charge

air cooler and the exhaust turbocharger and remove the V-ribbed belt pulley with the vibration damper.

WARNING!

Observe measures when disconnecting the battery Electrical System; Rep. Gr. 27.

WARNING!

Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully.



15-1 page 7

15

Release screws -4- and remove front air guide pipe with air guide hose; to do so raise the retaining clips -1- and -3-.

Remove the exhaust pipe from the exhaust turbo-charger, slacken the clamping sleeve and push the exhaust pipe to the rear Chapter 26-1.

Release screws -1- and -2- and remove support for turbocharger.

Collect any engine oil which flows out with a cloth.

Remove the oil return line -3- at the cylinder block. Unscrew oil feed line from turbocharger, exhaust

manifold and from coolant pipe and lay it to one side. Remove connection pipe of exhaust gas recirculation

between mechanical valve and exhaust gas recircula-tion radiator Chapter 26-2.

Remove the timing belt Chapter 13-1. Remove camshaft sprockets and pull off hubs for

camshafts Chap. 13-1. Remove toothed belt tensioning pulley. Release screws -2...4-. Unscrew pin screw -1- with two M8 nuts tightened up

opposite one another. Screw out screw -5- and remove Hall sender -G40-

from cylinder head. Disconnect all remaining plug connections at cylinder

head and lay aside the electrical lines. Unscrew fixing screws of oil dipstick guide, pull guide

out of the cylinder block and for removal pivot fowards.

Disconnect hose of vacuum reservoir, unscrew screw and remove reservoir from bracket. Then remove the support.

Separate all remaining coolant, charge air and vacu-um hoses and pipes from the cylinder.

Note



15

Screw the bracket -T10014- into the threaded hole above the coolant pump. Tighten screw for bracket to 20 Nm.

Support engine from underneath. Offset hook of -MP 9-200- for supporting device

-T30099- from the right lifting eye of the engine into the lug of the bracket -T10014- and preload engine via the spindle, do not lift.

Remove cylinder head cover 15-1 page 3.

Release screws -1- -3- and -5-. Loosen screws -2- and -4- and release alternately in

several stages.

Do not pull out screws of the valve-lever shaft, so that the individual parts on the valve-lever shaft remain attached. If necessary mark assignment of the individual parts.

Remove valve-lever shaft. Unscrew inner screws of bearing frame -610-.

Note



15-1 page 9

15

Follow the specified order for loosening cylinder head bolts.

Raise cylinder head.

Installing

Carefully remove residual sealant from the cylinder head and cylinder block. Make sure this does not cause any extended scoring or scratching.

There must not be any oil or coolant present in the blind holes for the cylinder head bolts.

Replace cylinder head bolts. When undertaking assembly replace self-locking nuts

and screws as well as gasket rings and gaskets which have been tightened

Date post:	24-Nov-2015
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Engine 2.0 103 Kw Tdi Pd, 2.0 100 Kw Tdi Pd

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