Remove exhaust manifold bolts and remove manifolds. To install, reverse removal procedures. Ensure exhaust system is aligned so components are free of stress. Replace all self-locking nuts. Tighten exhaust manifold bolts to specification. Installing cylinder heads supplied as replacement parts can be used on either the left or right-sides of the engine. A core plug sealing cap must be installed in the front end of the cylinder head in each case.
DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons.
Engine must be cool before proceeding with cylinder head removal. On A4 and A6 models, remove front bumper. Place lock carrier into service position. On all models, remove trim cover from top of engine. Remove noise insulation panel from under engine. Obtain radio anti-theft code if equipped , and disconnect negative battery cable.
Drain coolant from radiator. Remove coolant drain plug from engine. Remove air intake hose with MAF sensor and throttle valve control module.
Noting installed position for reassembly reference, disconnect all necessary electrical and vacuum connections to facilitate cylinder head removal. Remove intake manifold securing plate at rear of manifold. Remove serpentine drive belt. Remove timing belt from camshaft sprockets. It is not necessary to completely remove timing belt from crankshaft sprocket. Disconnect exhaust pipes from cylinder heads.
Unbolt exhaust system from transmission bracket. Remove fuel injector harness connectors from fuel injectors. Unbolt fuel rail from intake manifold. Remove fuel rail and injectors as an assembly. Unbolt bracket for ignition coils and set aside.
Remove intake manifold. Remove secondary air system connection pipe below intake manifold. Unbolt coolant pipe at rear of cylinder head. On driver side cylinder head, remove camshaft sprocket using sprocket puller. Remove rear inboard timing belt from drive side cylinder head. Unbolt coolant pipe at front of cylinder head. Remove cylinder head covers. Measure cylinder head height and warpage. If warpage exceeds specification, machine cylinder head.
If machining causes cylinder head height to 2 Clean all oil and coolant from blind holes in cylinder block. Carefully clean cylinder head and cylinder block sealing surfaces, ensuring nor scoring or scratches are formed. Only remove new cylinder head gasket immediately before installation. Install cylinder head gasket with "oben" mark or part number facing up.
Before installing cylinder head, ensure camshafts are set to TDC of No. Place No. Install cylinder heads on cylinder block. Install NEW cylinder head bolts. Hand tighten cylinder head bolts. Tighten cylinder head bolts in correct sequence. It is not necessary to retorque cylinder head bolts after completing repairs. To complete installation, reverse removal procedure. Tighten all fasteners to specification. Before installing valve cover and new gasket, apply small amount of sealant at 4 corners of cylinder head mating surface.
Install timing belt. Install viscous fan and serpentine belt. Fill and bleed air from cooling system. Coat outside circumference of core plug sealing cap with sealant AMV Using needle Bearing Drift VW , drive in core plug until outside rim is flush with end of chamfer in cylinder head.
Remove sealing plug from hole in left side of cylinder block. Ensure TDC hole can be seen or felt through sealing plug hole. Install Crankshaft Holder into sealing plug hole to prevent crankshaft from rotating.
Remove timing belt. Using Seal Remover , remove crankshaft seal. Unscrew inner part of Oil Seal Extractor 2 turns about 3 mm out of outer part and lock with knurled screw. Lubricate thread head of oil seal extractor, place it in position while applying firm pressure screw it as far as into oil seal.
Loosen knurled screw and turn inner part of extractor against crankshaft until oil seal has been extracted. This seal can be identified by a wider sealing lip that is threaded. There is also no annual sealing ring on the seal. It is installed dry. The seal MUST be installed with the direction arrow on the face of the seal facing the direction of rotation of the crankshaft. Manufacturer requires replacing crankshaft sprocket center bolt if loosened or removed. Press seal in flush with Installing Sleeve Tighten crankshaft sprocket bolt to specification.
Reassemble in reverse order. Reinstalling a used belt in reversed direction could damage the belt, and cause engine damage. For Passat, go to next step. For A4 and A6, move lock carrier into service position. On all models, remove serpentine belt and viscous fan. Rotate crankshaft using center bolt so that timing marks are aligned.
Remove upper timing belt guards. Check position of camshafts. Larger holes of camshaft securing plates located on front of camshaft sprockets must be on inside and must align. If camshafts are in correct position, go to next step. If larger holes are positioned to the outside, rotate crankshaft one turn further. Go to next step. Personal injury may result if using finger to check for TDC hole. Remove sealing plug from alignment access hole in left side of engine block.
Ensure that hole in crankshaft is visible or be felt through alignment access hole. Install Crankshaft Holder into alignment access hole to prevent crankshaft from rotating.
Remove serpentine belt tensioner. Remove center and right timing belt covers. If timing belt is to be reused, mark belt running direction with marker or crayon. NOTE: Timing belt tensioner is oil-dampened; compress it by slowly applying constant pressure. Compressing tensioner too quickly could damage it internally. Using an 8-mm wrench, turn timing belt tensioning roller clockwise until tensioning lever compresses tensioner so that a pin 2 mm in diameter can be inserted into plunger.
Insert pin and release tension. When removing vibration damper, it is not necessary to remove center bolt on vibration damper. If removed, the center bolt must be replaced with new bolt. Remove vibration damper bolts around center bolt.
Remove vibration damper. Remove serpentine belt idler pulley. Remove timing belt cover. Remove camshaft sprocket securing bolts and securing plates.
Install a 10 mm bolt in center of camshaft. Install Sprocket Puller on camshaft sprocket. Remove camshaft sprockets. Reinstall both camshaft sprockets, together with locking plate, and hand tighten bolts. Camshaft sprocket must be able to move on tapered camshaft. Repeat for each camshaft. Install Camshaft Holding Bar Use an 8-mm wrench to turn timing belt tensioning roller clockwise until tensioning lever compresses, and remove spring pin.
Using a torque wrench with an 8 mm hex bit, apply 11 ft. This ensures timing belt tensioner has expanded completely and properly tensioning belt. Tighten camshaft sprockets to specification. Install serpentine belt and viscous fan.
On A4 and A6, secure lock carrier to body. With ignition off, rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket using puller. Remove rear inboard timing belt guard. Remove valve cover. Clean camshaft drive chain and chain sprockets. Moving only the camshafts, align the marks on the camshaft sprocket with arrows on the bearing caps. Using paint, mark chain and sprockets opposite arrows on bearing caps.
Distance between both arrows and between paint markings is 16 rollers on the chain. Carefully compress camshaft adjuster using Chain Tensioner Tighten to keep slight pressure on chain between camshafts. DO NOT overtighten camshaft adjuster. Unbolt camshaft adjuster. Remove the following bearing caps. Evenly loosen bearing caps No. Identify each cap for installation in original position.
Remove and place in correct order for reassembly in original position. Remove camshafts together with camshaft adjuster. If reusing camshafts, inspect for wear. This is an interference engine. Pistons must not be positioned at TDC during assembly. Apply clean engine oil to camshaft contact surfaces. Install chain onto both camshafts.
Install 2 Before installing camshafts, verify position of chain and chain sprockets paint markings. Install both camshafts in cylinder head together with camshaft adjuster. Install camshaft bearing capsNo. Casting of arrows on intake side point to chain. On exhaust side, arrows point to exhaust manifold. Evenly tighten bearing caps No.
Lightly bearing caps No. Install bearing caps No. Evenly tighten bearing cap bolts to specification. Remove Chain Tensioner Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular valve train noise is normal when starting engine. Start engine and run until cooling fan cycles at least once.
Increase engine speed to RPM for 2 minutes or test drive vehicle and observe valve train noise. If valve train noise is still considered noisy, go to next step. Turn engine off.
Rotate crankshaft until camshaft lobes point upward on lifter being checked. Using a wooden or plastic wedge, push down on top of lifter. Try inserting a. If feeler gauge fits between top of lifter and camshaft, replace faulty lifter. If irregular valve noise occurs repeatedly on short trips and disappears after extended driving, oil check valve must be replaced. For help in identifying components and component locations, refer to Fig.
Remove camshaft drive sprocket. Unscrew inner part of Oil Seal Extractor oil seal extractor 2 turns about 3 mm out of outer part and lock with knurled screw. Lubricate thread head of Oil Seal Extractor , place it in position while applying firm pressure screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
Installation Left Side Camshaft. DO NOT oil sealing lip or outer circumference of oil seal. Clean contact surface and sealing surface. Install camshaft drive sprocket. Removal Right Side Camshaft. Remove CMP sensor shutter bolt and conical washer. Noting installed position for reassembly, carefully pry off shutter.
Unscrew inner part of 2 turns about 3 mm out of outer part and lock with knurled screw. Lubricate thread head of oil seal extractor, and place it in position. While applying firm pressure, screw it as far as into oil seal. Installation Right Side Camshaft. Clean contact surface and sealing surface head and camshaft. Install CMP sensor and conical washer in original position. Install and tighten bolt. The following procedure is given assuming the transmission has been removed or the engine has been removed for servicing.
Holding drive plate stationary, remove drive plate bolts. Manufacturer requires using NEW drive plate bolts on installation. Mark drive plate and shims for reference. For vehicles equipped with an automatic transmission, inspect bushing at crankshaft flange.
Install drive plate and shims in original locations. Install OLD bolts into flange. Check dimension "A" at 3 evenly space points. Find average of readings. Specification should be approximately If specification is not correct, different size shims are available from manufacturer to obtain correct clearance. When correct shim size is installed, install NEW drive plate bolts. Tighten to specification.
If installing new crankshaft or engine block, ensure torque converter bearing bushing is installed correctly. The following procedure is given assuming the transmission the engine has been removed for servicing. Loosen the bolts in a cross pattern and remove drive plate. Inspect pilot needle bearing. If installing new drive plate, install pilot needle bearing. Install flywheel in reverse order of removal.
Tighten NEW bolts to specification. If reusing original pressure plate and flywheel, check for White alignment marks. If present, align marks on reassembly. Remove transmission. Remove flywheel. Using an appropriate puller, remove pilot needle bearing. Use Bearing Driver , or equivalent, to install pilot needle bearing. Ensure completed engine or crankshaft has bearing bushing installed. The bushings must be installed before installing the driveplate.
Removal and installation procedure not provided by manufacturer. Remove drive plate or flywheel. If not replacing seal together with flange, go to step 5.
If replacing seal together with flange, drain engine coolant before removing flange. Remove flange and oil seal together. Install NEW flange and oil seal. Tighten crankshaft oil seal carrier bolts to specification. Fill and bleed cooling system. Using Seal Extractor , remove seal from carrier. Clean running and sealing surfaces. DO NOT lubricate sealing lip or outer edge of seal before installing. Using assembly aid if provided with new seal press seal onto crankshaft.
Drain engine coolant. Place lock carrier in service position. Remove timing belt guard. Remove thermostat housing bolts. Housing is located near front of passenger side cylinder head. Remove thermostat. Lube new O-ring gasket with coolant. Install thermostat with bleeder valve at top 12 o'clock position. Tighten thermostat housing bolts to specification.
Disconnect all necessary electrical connectors from front of vehicle. Remove serpentine belt and viscous fan. Remove bracket for viscous fan. Remove water pump bolts and remove pump. Install new gasket with water pump. Tighten water pump fasteners to specification. For help in identifying components and component locations, refer to illustrations Fig.
Remove engine noise insulator undercover. Drain engine oil. Unbolt left and right swaybar stabilizer bracket bolts 4 from mounting bracket. Lower swaybar stabilizer not more than 10cm 3. If vehicle is equipped with automatic transmission, unbolt oil cooler pipe line bracket from right side oil pan. Remove lower oil pan. Ensure oil pan surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with hand drill and plastic brush instead of a flat scrapper.
Install gasket. Install 2 bolts diagonal to each other to hold up pan. Install the rest of the bolts and hand tighten. Also anybody swapped valve seals on their own Last edited by jibberjive; at PM. Either are easy enough to grab. Just curious on which are more desirable. Originally Posted by jibberjive. As far as coolant ports are concerned, they've both got the same ones.
Originally Posted by gearhead No, not plugged from the factory, just already plugged in the pictures. You'll need to plug either set of heads. GURU energy drinks www. The only way you could change your compression would be via pistons or headgaskets. Get whatever head is cheaper as they are both "bolt on". Connectivity products demand interoperability, with corrosion-resistant gold-plating. We take pride in our items and selection for you. They will clamp your phone tightly to secure your phone on smooth and bumpy roads.
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