Ray's World

1.8L Engine
Fig. 1: Exploded view of the camshaft mounting and related components — 1.8L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
4. Place the lock carrier into the service position.
5. Remove or disconnect the following:
* Accessory drive belts
* Engine covers
* Timing belt upper cover
6. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at Top Dead Center (TDC).
7. Remove or disconnect the following:
* Timing belt tensioner by loosening it using Torx® wrench T45
* Belt from the camshaft gear by pushing the tensioner downward
* Torx® bolt and swing the tensioner assembly bracket forward
* Valve cover
* Cam gear retaining bolt by loosening it using retainer tool 3036
* Camshaft gear
* Camshaft Position (CMP) housing sensor and shutter wheel
* Hydraulic chain tensioner by securing it with bracket tensioner tool 3366

Fig. 2: Do not overtighten the chain tensioner tool 3366, it can be damaged — 1.8L

8. Verify that the camshafts are at TDC for the No. 1 cylinder. Both camshaft markings must align with arrows on the bearing caps.
9. Clean the drive chain and the cam chain gears opposite both arrows on the bearing caps. Matchmark the installed position using paint.

NOTE: The distance between the 2 arrows/paint marks is equivalent to 16 drive chain rollers and the notch on the exhaust camshaft is slightly offset inward toward the drive chain roller.

Fig. 3: To ensure proper installation, matchmark the chain-to-camshaft position — 1.8L

Fig. 4: Camshaft bearing cap identification — 1.8L engine

10. Remove or disconnect the following:
* Bearing caps No. 3 and 5 from the intake and exhaust camshafts
* Double bearing cap
* Both bearing caps from the chain gears on the intake and exhaust camshafts
* Hydraulic chain tensioner retaining bolts
* Intake and exhaust manifold bearing caps No. 2 and 4 by loosening them in an alternating and diagonal sequence
* Camshafts with the hydraulic chain tensioner

To install:

Fig. 5: To ensure a proper seal, be sure to apply sealant to the hatched area — 1.8L

11. Replace the rubber/metal chain tensioner gasket and apply sealant to the hatched area, as shown.
12. Install or connect the following:
* Drive chain on the camshaft

NOTE: If installing the old chain, align the paint marks with the camshaft marks. If installing a new chain, the distance between the notches A and B on the camshafts must equal the distance between 16 drive chain rollers.
* Hydraulic chain tensioner by sliding it between the drive chain
* Camshafts with the chain tensioner lubricated with engine oil into the cylinder head
NOTE: When installing the bearing caps, verify the markings on the caps are readable from the intake side of the cylinder head.
* Intake and exhaust camshafts bearing caps No. 2 and 4. Tighten them in an alternating diagonal sequence to 84 inch lbs. (10 Nm).
* Both the intake and exhaust camshafts bearing caps on the chain sprockets. Tighten the bolts to 84 inch lbs. (10 Nm).
13. Verify the correct positions of the camshafts.
14. Remove the bracket tensioner.
15. Install or connect the following:
* Cylinder head-to-double bearing cap mating surface by lightly coating it with sealant. Tighten the remaining bearing caps to 84 inch lbs. (10 Nm).
* Camshaft gear. Tighten the bolt to 48 ft. lbs. (65 Nm).
* CMP shutter wheel and housing cover
* Valve cover
16. Align the camshaft gear and the vibration damper with the TDC markings.
17. Install or connect the following:
* Timing belt
* Accessory drive belts and the engine cover
* Lock carrier
* Negative battery cable
18. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function

CAUTION
After installing the lifters or the camshaft(s), the engine must NOT be started for at least 30 minutes. Otherwise the valves could strike the pistons. Rotate the engine by hand, at least 2 revolutions, to ensure that the valves do not strike the pistons.

19. Check the oil level before starting the engine.
20. Set the clock to the correct time.
21. Enter the radio security code.

NOTE: DTCs may be stored when harness connectors are detached.

22. Read the DTCs and clear the fault codes.
23. Adjust the headlights.

http://forums.vwvortex.com/zerothread?id=3425946

Another Head Removal DIY to use as a supplement to

Quote, originally posted by CYLINDER HEAD REMOVAL & INSTALLATION »

CAUTION Cylinder head removal should not be attempted unless the engine is cold. 1.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: * Front bumper 3. Place the hood lock carrier into the service position. 4. Turn the ignition switch to the OFF position. 5. Remove or disconnect the following: * Negative battery cable * Accessory drive belt * Cooling fan 6. Drain the engine coolant. 7. Remove or disconnect the following: * Intake manifold * Accessory drive belts * Wastegate bypass regulator valve * Evaporative Emissions (EVAP) canister purge regulator valve * Power outage stage * Mass Air Flow (MAF) sensor * Air cleaner housing * Engine Temperature Control (ETC) and the temperature II sensor harness connector * All connections from the cylinder head * Crankcase breather line * Oil supply line at the cylinder head * Exhaust manifold heat shield * Turbocharger from the exhaust manifold * Coolant hose to the heat exchanger at the rear of the cylinder head * Upper timing belt cover 8. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at TDC. 9. Using Torx® wrench T45, loosen the timing belt tensioner. 10. Push down on the tensioner and remove the belt from the camshaft gear. 11. Remove or disconnect the following: * Torx® bolt and swing the tensioner assembly bracket forward * Valve cover * Cylinder head bolts, in sequence, as shown * Cylinder head 12. Clean the gasket mating surfaces. 13. Clean and dry out the cylinder head bolt holes.To install: NOTE: Always replace the cylinder head bolts, self-locking nuts, bolts, gaskets and O-rings. NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart. 14. Before installing the cylinder head, set the crankshaft and camshaft to TDC for the No. 1 cylinder. 15. Loosen the turbocharger support bracket to reduce the likelihood of any tension while installing the cylinder head. 16. Install or connect the following: * Head gasket with the part number visible from the intake side * Cylinder head * New cylinder head bolts, tighten by hand 17. Tighten the new cylinder head bolts in sequence in 2 steps: Step 1: 44 ft. lbs. (60 Nm) Step 2: additional 1⁄2 (180 degree) turn NOTE: It is not necessary to retighten the cylinder head bolts. 18. Install or connect the following: * Turbocharger to the exhaust manifold using new gaskets and the bolts coated with Hot Bolt Paste G 052 112 A3. Tighten the bolts to 26 ft. lbs. (35 Nm). * Turbo support bracket. Tighten the bolts to 33 ft. lbs. (40 Nm). * Valve cover * Timing belt * Accessory drive belts * Exhaust manifold heat shield * Oil supply lines to the cylinder head. Tighten the retaining straps to 15 ft. lbs. (20 Nm). * Crankcase breather * Any other items removed during disassembly * Coolant temperature sensors * Air cleaner housing 19. Fill the engine with coolant and bleed, if necessary. 20. Connect the negative battery cable. 21. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function. 22. Check the oil level before starting the engine and top off, as necessary. 23. Set the clock to the correct time. NOTE: DTCs are stored when harness connectors are detached. 24. Clear the fault codes, as necessary. 25. Install or connect the following: * Hood lock carrier assembly * Front bumper 26. Adjust the headlights.

http://forums.vwvortex.com/zerothread?id=3425946

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Since quite a few guys asked me how, plus the fact that I didn’t have a writeup to follow when I had to remove my head in my driveway, I just had my guys on AZ/AW. So as a token of thanks, I just threw this together to avoid future repetitive questions.

Ok here we go:

Do you have to remove the timing belt to take off the head? Yes and No.

I do not remember the exact allen sizes because I bought the Switch-out allen key tool from Autozone, this helps tremendously and is only $10, Everything else is off the top of my head.

Plan to take everything apart , unless you know the secret to put the belt on w/o putting it in service position, i know how to do it , but didnt have the tools, the hard part is putting the belt back on out of service pos. and tensioning it w/o the right tools, but dont sweat it.

There are writeups for the Timing belt, but not for head removal.- Plan on putting the car in service position, then work on the head. Get down to the timing belt (service position) Then just remove the Hydraulic dampener and take the belt off – Dont forget the cam sensor . If you are in a rush,and are replacing the belt you can CAREFULLY remove the belt from the cam gear– Pull side to side then easily use a blunt object to slowly push the belt off the teeth, side by side, carefully and slowly.

Once its off , start disconnecting the exhaust manifold bolts first-The bolt (size 17) nearest the head is a toughguy, use a small ratchet in there and remove it while it still has room to be pulled out, then use an open ended wrench to take it out.

After the EM, start at the Throttle body , remove hose and throttle body (4 screws, size 6 or 8 allen i believe) Remove throttle cable and 2 bolts holding it in. Unhook cruise control nipple. Now is the time to remove the lines under the Intake manifold. There are two. Remove those hoses easily and disconnect throttle body sensor wire. Now remove the 10mm Allen bolt for the IM brace. Then, work your way to the black cooling line that runs from the upper rad hose. Remove those screws holding the metal hose down to the IM. Then there is a connection at the corner of the head that goes down to the filter . Disconnect that hose (using pliers), then start working at the rear head coolant flange. 2 size 10 bolts await you. Try to unscrew these with care, they are sensitive and so is the flange. After that, remove remaining hoses from Coolant flange, 2 I believe , 1 rear , 1 right side. Replace all those gaskets and do not lose clips. Pull and replace Coolant temp sensor while you are at it.

While back there, remove the 2 10mm bolts that connect the rear head flange to the radiator hose. After that, remove the bolt holding down the metal coolant line going across the head and swing out of the way.

Remove Fuel rail and injectors. Youll need a 6mm Allen to get the 2 bolts holding down the rail. After they are out, the injectors pop out with a straight pull. Now remove the 10 10 mm bolts holding down the VC. After that, remove coil pack ground (size 10 as well) then, remove coilpacks and peel them back , resting in them behind the firewall. Remove PCV line that is bolted to VC ( 2 allen bolts) Remove valve cover and carefully set aside, upside-down. Your almost there.

Now: Onto removing the headbolts-

There are two tools that are required for some.

For earlier B5’s (97-98.5, maybe 99.5), you need those two. (Go figure)

First, Go to Napa. Get their headbolt kit (GM) , Its cheap. You are looking for a 12 point.

One of the 5 tools is going to fit our headbolts. From there the tool is short, It’ll only remove the center headbolts and not the bolts in the corners of the Head, as they have a deep well. Well, To solve this problem, I welded a ratchet extension onto the tool itself. ( Or pay someone, cant be more than $5) Make sure they (or you) grind down the weld in order to avoid scraping the walls of the head.

Newer B5 Guys : : You need this Poly-Drive tool::

From here – http://www.zdmak.com/wbstore/main.as…CTMP=1&LowCt=0

(its a 1/2″ drive type)

Earlier B5 guys, You have to have this as well after removing headbolts because when you buy new ones (which you have to), they will be Poly-Drive bolts.

First, Naturally, Remove the Valve cover– Ten 10mm nuts hold it on, as well as the coil packs. They are easy to remove, But remember when pulling the VC up, Pull Evenly from each side, or else it will get stuck and its pretty annoying if you dont.

Removing Headbolts

Removing the headbolts requires a removal pattern in this order:

(Intake cam being the Bottom Row)

1 7 9 5 3

[4 6] 10 8 2 — Parenthese= Plastic Splash cover

They loosen up easy, but make sure you keep unscrewing, as the threads are long.

The head is ready to come off. Put the valve cover back on (just one screw will do) If you are doing it alone like I did, start to break it free from the block easily and rotate and move it around. After it gives weigh, Grab the exhaust manifold and the base of the runners and lift evenly and have something right next to you ready to rest it on, Its not light. Easily place it upside down, resting on the VC on a soft surface, I used a “boogie board” which was made out of strong foam.

And her head’s off:

The red dots signify my bent valves (if you can’t already tell)

While you have the head off, now is a great time to replace a few more things and one mandatory thing:

-I cleaned my squish area just a bit and as well as the surrounding area. Some may argue that it needs to be dirty to form a nice seal, But after cleaning mine, I had zero issues.

-Replace stock oil feed line to the turbo

-Replace PVC pipe from the block , Part number 058 103 213 (wasnt expensive)
http://www.scottweese.com/images/pcv/old_new.jpg

This is a culprit to boost loss and very hard to replace w/ the IM on.

- Onto the mandatory part, you guessed it, The Head gasket ($60)

When you are ready to install the head (dont remove gasket from pkging until you are ready), installation is reverse of removal w/ a few exceptions:

-Remember to PROPERLY install headgasket rightside up with Audi VW emblem facing UP in the lower right hand corner of the head, quite a few people had made this mistake and had to repeat the process all over again.

-Replace coolant

-Remember to replace all coolant line and flange washers

And most importantly,

Install Headbolts in this specific order

Intake cam being the bottom row-

10 4 2 6 8

[7 5] 1 3 9

Start w/ your regular 1/2″ ratchet then torque to 44 lb Ft (60 NM) After that, Take your Regular half inch ratchet and Give an additional HALF TURN. I used two quarter turns for extra control.

- Try to get some help installing the Head if you can- youll need it when trying to line it up with the points. If you cant, take your time and set easily. After it is set, test to see if the head easily moves out of place, if it does, then its not in the right place.

Before you put the VC on, pour some oil over the cams and valves for startup and start connecting the exhaust mani and the rest after you set the Timing belt to TDC and your all done and saved yourself massive amounts of money.

And thats it! Whole process maybe took an hour and a half , wasnt hard right?

NOTE: When setting engine to TDC, set crank a few teeth before TDC if the head isnt already at TDC. This will avoid any compression and allow you to adjust the cam sprocket accordingly with the safety of avoiding the bending of valves.

Now enjoy putting everything else back together!