Replacement
NOTE: During service procedures, refer to the illustration above and the information below
Component Notes And Information
NOTE:
^ When installing an exchange cylinder head (with camshaft), the contact surfaces between hydraulic lifter and cam must be oiled after installation.
^ The plastic protectors (fitted to protect the open valves) should only be removed just before installing the cylinder head.
^ If the cylinder head is replaced, completely replace the engine coolant
1 Intake manifold
- Removing and installing refer to Removal and Installation below
- First tighten to lower intake manifold, then to the two rear supports (items 7 and 3)
- Disassembly and assembly refer to Disassembly/Assembly. Service and Repair
2 Bolt
- Tighten to: 25 Nm (18 ft lb)
3 Right rear support
- Between intake manifold and cylinder head cover
4 Throttle Valve Control Module
- Heated by coolant
- Removing and installing: refer to Powertrain Management
5 Connection
- Removing and installing: refer to Powertrain Management
6 Exhaust Gas Recirculation (EGR) valve
- Refer to Powertrain Management
7 Rear left support between intake manifold and cylinder head
8 Cap
9 Gasket
- Replace if damaged
10 Vacuum hose
- To EGR valve/intake manifold junction piece
- Refer to Powertrain Management.
11 Oil filler pipe
12 Nut
- Tighten to: 10 Nm (7 ft lb)
13 O-ring
- Replace if damaged
14 Cylinder head cover
- Removing and installing see procedures below
- Replace if damaged or leaking
15 O-ring
- Always Replace
- Coat with oil before assembling, insert in camshaft sprocket cover (item 16)
16 Camshaft sprocket cover
- Can be removed and installed with cylinder head installed
- Coat sealing surfaces with AMV 188 001 02
- If only the camshaft sprocket cover has been removed; prepare cylinder head gasket for assembly, refer to Fig. 2 below
17 Spacer ring
18 O-ring
- Always Replace
- Oil before installing
19 Camshaft Position sensor -G40-
- Checking, refer to Powertrain Management
20 Bracket
- For -G98- EGR Temperature sensor, 2- pin connector
21 Seal
- Always Replace
22 Chain tensioner
- Tighten to: 30 Nm (22 ft lb)
- For double chain
- Bleed before installing, refer to Fig. 2 of part 2 of Disassembly/Assembly To Major Components. Procedures
CAUTION: Only turn engine when the chain tensioner is installed
23 Ground connection
24 Bracket
25 Ignition Coil -N152-
- Checking, refer to Powertrain Management
26 Bracket
- For fuel injector connectors (item 35)
27 Thermostat housing
- Disassembly and assembly, refer to Cooling System.
28 O-ring
- Always Replace
29 Cylinder head gasket
- Always Replace
- If replaced, completely replace the engine coolant
30 Cylinder head
- Check for distortion refer to Fig. 1 below
- Installing: refer to "Installation" below
- If replaced, completely replace the engine coolant
- Note sequence when loosening and tightening
- Refer to "Installation" below
31 Cylinder head bolt
- Always Replace
- Note sequence when loosening and tightening
- Refer to "Installation" below
32 Lower intake manifold gasket
- Always Replace
- Note installed position
33 Ribbed belt tensioner
- Ribbed belts, removing and installing: refer to Replacement. Service and Repair
34 Positive Crankcase Ventilation valve
- Arrow on valve points toward intake hose
- Refer to Powertrain Management,
35 Connector
- For injectors N30, N31, N32, N33, N83 and N84
- Mounted to bracket (item 26)
36 Retainer
- For Secondary Air Injection pump motor
- Refer to Powertrain Management.
Removal
Special Tools, Testers And Auxiliary Items
- 3277A installation tool
- VAG 1331 Torque wrench 5 to 50 Nm (4 to 37 ft lb)
- VAG 1921 spring clip pliers
Procedure
CAUTION: Obtain radio code before disconnecting battery ground strap.
- Switch OFF ignition
- Disconnect battery ground strap
NOTE: Replace all cable ties which were opened or cut to remove the engine and replace them in their original position
- Remove sound dampening tray
- Remove radiator grille
- Remove lock carrier mounting bolts -1- on left and right side
- Hinge lock carrier forward (with radiator) -arrow-
- Disconnect heater element harness connector (on intake hose)
- Remove intake hose between upper Air Cleaner and Throttle Valve Control Module J338 together with the Positive Crankcase Ventilation valve, refer to Powertrain Management.
- Disconnect harness connectors from EGR valve -1-, Throttle Valve Control module -2-, and Intake Air Temperature sensor -3-
- If installed, disconnect 2-pin harness connector from EGR Temperature sensor -arrow-
- Disconnect white 3-pin harness connector from Knock sensor 1 -arrow-
- Release wiring from clips behind intake manifold and on EGR valve
- Remove spark plug connectors using 3277A release tool and unclip the ignition cables from the ignition cable guides
- Detach accelerator cable (do not remove locating clip) from support bracket and Throttle Valve Control Module
- Mark coolant hoses -1- and -2- from Throttle Valve Control Module
- Pull off hoses using VAG 1921 hose clamp pliers (after first releasing pressure from cooling system)
- Seal coolant hoses
- Pull off breather hose from EVAP canister purge regulator valve -3-
- Disconnect vacuum hose to brake servo from intake manifold
CAUTION: Fire Hazard. Do NOT smoke or have anything in the area that can ignite fuel.
- Using VAG 1921 hose clamp pliers, remove fuel return line -I- (blue or blue markings) and fuel supply line -2- (black or black markings)
CAUTION:
^ Fuel supply lines are under pressure!
^ Before disconnecting line connections; wrap a cloth around the connection, then release pressure by carefully pulling the hose off the connection.
- Disconnect vacuum hose -3- from Secondary Air Injection valve off of junction piece
- Disconnect line from exhaust manifold at EGR valve connection
- Disconnect fuel injector harness connectors and remove connector from retaining bracket
- Remove left rear support between intake manifold and cyl. head -arrow-
- Remove right rear support between intake manifold and cyl. head -arrow-
- Disconnect Secondary Air Injection system valve -1- and Secondary Air Injection system pump motor -2-
- Remove Secondary Air Injection pump motor, refer to Powertrain Management
- Remove Secondary Air Injection combi-valve, refer to Powertrain Management.
- Remove combi-valve connection at cylinder head, refer to Powertrain Management
- Remove dipstick guide tube
- Remove intake manifold mounting bolts
- Remove intake manifold assembly/Throttle Valve Control Module
When installing, note position of dowel sleeves in cyl head
NOTE: Seal the dipstick guide tube opening in the cylinder block and the -intake ports in cylinder head using a clean cloth.
- Remove cylinder head cover
Installation
- Install components in reverse order of removal
NOTE:
^ Replace cylinder head cover if damaged or leaking
^ Replace gasket between lower intake manifold and cylinder head cover
^ First tighten the intake manifold (including lower intake manifold) to cylinder head, then tighten both rear supports
^ Ensure that fuel lines are tight
- Replace engine coolant, refer to Cooling System.
- Adjust throttle cable, refer to Powertrain Management.
- Check Diagnostic Trouble Code (DTC) memory, refer to Powertrain Management.
- Refer to tightening torques table below.
