Engine codes AEG, AVH, AZG, BEV

Fig 1: Identifying Special Tools - Cylinder Head, Removing And Installing (engine Codes AEG, AVH, AZG, BEV)

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Engine code BBW. Refer to Engine code BBW

Special tools and equipment

V.A.G 1306 Drip tray
V.A.G 1332 Torque wrench (40 to 200 Nm)
VAS 5024 Assembly tool for spring-type clips
3450/2A Guide pins

3450/3 Removal tool
3452 Key (for Polydrive cylinder head bolts)

Fig 2: Identifying T10020 Two Hole Pin Wrench

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T10020 Two hole pin wrench

Fig 3: Identifying T10112 Fitting Tool

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T10112 Fitting tool

Requirements

Engine must only be hand touch warm.

Removing

CAUTION:

When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE: During this procedure the battery Ground strap must be disconnected. Therefore, please check first whether a coded radio is installed. Obtain the radio code first if necessary.

With ignition switched off disconnect battery Ground (GND) strap.
Remove engine cover.
Drain coolant. Refer to Cooling system, draining and filling .

WARNING:

The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.

Engine codes AEG, AVH, AZG, BEV

Fig 4: Locating Fuel Supply & Return Lines & EVAP Canister Purge Regulator Valve

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Pull fuel supply line -1- and fuel return line -2- off connections
Disconnect hose -3- from solenoid valve for Evaporative Emission (EVAP) Canister Purge Regulator Valve

Engine code BEV

Fig 5: Disconnecting Fuel Supply Line Off Union By Pressing Locking Ring Into Union

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Pull fuel supply line -1- off union by pressing locking ring -2- into union -3-.

Continued for all engines

Seal lines to avoid contamination of fuel system. Refer to Air cleaner, disassembling and assembling .
Remove air cleaner with intake hose and secondary air line.
Remove intake manifold upper part. Refer to Intake manifold upper part, removing and installing .
Disconnect all necessary coolant, vacuum and intake hoses from intake manifold upper part/cylinder head.

Pull off/discount all electrical connections/wiring as necessary from cylinder head and lay aside.

NOTE: Seal the intake ports in the intake manifold lower section with clean cloths.

Remove connections with coolant hoses.
Remove suction and pressure lines from secondary air pump motor.
Remove pressure line retainer.
Unbolt secondary air pump motor bracket and remove.

Disconnect following connections:

Fig 6: Identifying Secondary Air Injection Pump Motor -V101- & Harness Connector

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-1- for Secondary Air Injection (AIR) Pump Motor -V101- -2-.
Camshaft position (CMP) sensor -G40-
Knock Sensor (KS) 1 -G61-
For injectors -N30-, -N31-, -N32-, -N33-, (unclip cable guide).

Fig 7: Engine Coolant Temperature Sensor -G62-

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Engine Coolant Temperature (ECT) sensor -G62- (arrow).

Knock Sensor (KS) 1 -G61- from clip on generator bracket.
Remove wiring harness from fuel rail and lay to one side.
Unclip wiring harness on left next to cylinder head.
Disconnect wiring from spark plus using tool T10112.

Fig 8: Return Line Clip & Oil Dipstick Retainer Bolt

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Unclip return line from clip -1-.
Remove bolt -2- from oil dipstick retainer.
Remove cover for Heated Oxygen Sensor (HO2S) connector.
Disconnect Heated Oxygen Sensor (HO2S) -G39- connector and take wiring harness off heat shield.

Disconnect front exhaust pipe with catalytic converter,
Take off poly V-belt. Refer to Poly V-belt, removing and installing .
Remove bracket (Refer to Part I , item 2) from poly V-belt tensioning element.
Remove toothed belt guard upper part.

Fig 9: Aligning Mark On Camshaft With Mark On Toothed Belt Cover

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Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft 1. Mark on camshaft pulley must align with (arrow) on toothed belt guard.
Loosen tensioning roller and remove toothed belt from camshaft pulley.
Turn crankshaft back slightly.
Remove cylinder head cover.

Remove upper bolt from rear toothed belt guard.

Fig 10: Identifying Cylinder Head Bolts Loosening Sequence

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Loosen socket head bolts in sequence given and then remove.

NOTE: Use key 3452 for polydrive cylinder head bolts.

Carefully lift cylinder head off.

NOTE:

Always replace bolts.
There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head.
Do not remove new cylinder head gasket from its packing until immediately before installing.
Handle new gasket with extreme care. Damage will cause leakage.

Place cleans cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
Also prevent dirt and emery cloth particles from getting into coolant.
Carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100)
Carefully remove metal particles, emery residue and cloths.

If crankshaft has been turned: Set No. 1 cylinder piston to top dead center and then return crankshaft back slightly.

Fig 11: Identifying Guide Pins From 3450/2 A & 3450/3 Inserted Into Front Outer Threaded Holes For Cylinder Head Bolts

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To centralize, screw guide pins from 3450/2 A into front outer threaded holes for cylinder head bolts.

NOTE: Part number must be visible.

Install new cylinder head gasket.
Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
Remove guide pins through bolt holes with removal from 3450/3. To do this turn removal tool counter-clockwise, until pins are free.
Install remaining cylinder head bolts and tighten hand-tight.

Fig 12: Identifying Cylinder Head Bolt Tightening Sequence

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Tighten cylinder head in tightening sequence as follow:
Pretighten all bolts to 40 Nm.
Then tighten all bolts 1/4 turn (90 ° ) using a rigid wrench.
Then tighten all bolts again another 1/4 turn (90 ° ).

Further assembly is the reverse of the disassembling procedure.

NOTE: When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

Install cylinder head cover.

Tightening torque: 10 Nm

Install toothed belt and set timing. Refer to Engine codes AEG, AVH, AZG, BEV
Install poly V-belt tensioning element.

Tightening torque: 25 Nm

Install ploy V-belt. Refer to Poly V-belt, removing and installing .
Installing front exhaust pipe with catalyst to exhaust manifold. Refer to Exhaust system components, removing and installing .

NOTE: Reinstall wiring/lines to their original positions.

Fill with new coolant. Refer to Cooling system, draining and filling .
Connect battery Ground (GND) strap.

Vehicles with throttle (accelerator) cable

Adjusting throttle cable. Refer to Accelerator mechanism, servicing .

Continued for all models

Adapt engine control module to throttle valve control module. Refer to Adapting components and functions , Adapting functions and components.
Test drive vehicle and read Diagnostic Trouble Code (DTC) memory.
If DTC memory was erased or engine control module has been disconnected from permanent positive supply, regenerate readiness code. Refer to Adapting components and functions , Adapting functions and components.