Re: Low Compression 1990 200TQW IA Stage I

[quk@isham-research.demon.co.uk (Phil Payne)]

In message <c=US%a=_%p=U.S._House_of_Re%l=MSG04-981001161321Z-2542@msg04.house.gov> "Forhan, Thomas" writes:

> I'd appreciate any and all thoughts, and I am particularly interested in
> estimates of the time needed to R+R the head. Anyone know what the flat
> rate books suggest?

The engine is basically the same as the MB ur-quattro, although the
latter's engine bay is a _lot_ tighter and forces some rather strange
manipulations on you.  I just completed this checklist for MB head
removal - perhaps someone who's recently done an MC would be kind
enough to clean it up for that engine:

1. Disconnect battery, drain coolant and ground coil to chassis
2. Remove headlight trims, radiator grill, detach end of bonnet release cable & remove transom
3. Loosen hydraulic pump pivot bolt, slacken and remove adjuster and belt
4. Detach upper hose from radiator
5. Lift the hydraulic pump to access the lower bracket securing bolt, then remove the upper bolts to detach pump from cylinder head and tie back
6. Remove auxiliary radiator - bottom 10mm nuts need only be loosened and slide backwards
7. Remove injector cooling fan deflector, plug wires, plug wire shroud & distributor cap
8. Unplug Hall sender on distributor
9. Remove spark plugs to make engine easier to turn
10. Remove upper cambelt cover & turn engine to TDC (flywheel) using spanner on cam wheel bolt
11. Lock crankshaft at TDC with VAG tool #2084
12. Loosen water pump & rotate to loosen cambelt
13. If the cam is later to be removed from the head or if an exchange head is to be fitted, place a strong cable tie around the cam belt and break the cam gear retaining bolt free before pulling the belt free
14. Remove upper cam belt cover mounting stud and bolt securing backing plate to side of cylinder head
15. Unplug & unscrew injector cooling fan & turbo after-run water pump from side of engine
16. Unplug control pressure regulator, unbolt from side of block & place on metering head - fuel lines stay attached
17. Unplug cold start injector, unscrew from manifold & place on metering head - fuel line stays attached
18. Pull out injectors & place on metering head - fuel lines stay attached
19. Unplug fuel consumption potentiometer, fuel frequency valve and throttle body switch
20. Cut cable ties to air mass sensor
21. Loosely tie detached fuel pipes to metering head, undo fuel feed & return, pull off breather hose, disconnect accordion hose, unclip air filter housing & lift out entire fuel injection system
22. Remove the air filter and air filter housing
23. Tie loose loom back to filter housing bracket
24. Remove the crankcase & cam cover breathers
25. Disconnect injector cooling fan thermoswitch & remove heatshield  & coil grounding strap from cam cover
26. Remove right CV joint heat shield
27. Disconnect downpipe from centre exhaust section & detach downpipe from gearbox mounting
28. Using a 3/8" drive 13mm six-point socket & a taped UJ, undo wastegate to downpipe nuts - an assistant is usually required
29. Detach both vacuum pipes from wastegate
30. Unbolt wastegate from exhaust manifold & remove
31. Undo turbo oil & water connections & remove upper oil feed pipe
32. Detach downpipe from turbo & push aside
33. Detach turbo to intercooler hose
34. Detach turbo from manifold & remove
35. Detach accelerator cable
36. Detach temperature sender wire, wastegate main feed, wastegate control valve feed, ECU feed & differential lock feed from rear of head & manifold
37. Detach intercooler to throttle body hose from throttle body
38. Remove injector air supply hose
39. Using a mirror and "removal grade" Allen drivers, unscrew and remove the inlet manifold
40. Unbolt top hose from side of the head
41. Detach wire from temperature sender below hydraulic pump
42. Remove cam cover, gasket and rear plug
43. Slacken head bolts crosswise from outside inwards, one turn at a time
44. Remove cylinder head
45. If an exchange head is to be fitted, ensure that the blanking plug from the rear of the head is transferred to the new head, as well as both temperature senders
46. Removing the valves requires a 'deep reach' spring compressor, e.g., Sykes Pickavant 039500.

I figure the MB at about ten hours if you know what you're at.

--
 Phil Payne
 Phone: 0385 302803   Fax: 01536 723021
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