The ammended checklist for the MC head removal

[four.rings@mcione.com]

Phil Payne wrote:

> 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:

I would like to add few notes to the Phil's detailed procedure coz type-44
affords significantly more RE under the hood and allows to cut some corners:
 
> 1. Disconnect battery, drain coolant and ground coil to chassis
> 2. Remove headlight trims, radiator grill, detach end of bonnet release cable & remove transom

<---2a. Remove Intercooler. Do not remove headlight trims, do not detach end of
bonnet release cable & what is a "transom"?

> 3. Loosen hydraulic pump pivot bolt, slacken and remove adjuster and belt
> 4. Detach upper hose from radiator.
<---4a. Drain the coolant from the block.
> 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
<---6a. Disregard this step.
> 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
<---10a. Check TDC on the camshaft and the crankshaft sprockets.
> 11. Lock crankshaft at TDC with VAG tool #2084
> 12. Loosen water pump & rotate to loosen cambelt
<---12a. Don't move the pump if you are intending to reuse the timing belt (if
it has less than 30kmi).
You should be able to put the belt back on the camshaft sprocket.
> 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.
<---13a. Alternative way: put a big box end wrench on one of the cam lobes and
wedge it against the head. Break the 19mm camshaft nut loose.
> 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
<---15a. Disregard this step. Remove  both hoses from the aux coolant pump tho.
> 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
<---21a. Disregard this step.
> 22. Remove the air filter and air filter housing
<---22a.  Remove the air filter cover, not the whole 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
<---30a. Disregard this step. Remove the head with wastegate as one unit.
> 31. Undo turbo oil & water connections & remove upper oil feed pipe
<---31a. Plug the upper oil and water ports on the turbo with corks.
> 32. Detach downpipe from turbo & push aside
<---32a. Disregard this step. Remove the head with downpipe as one unit.
> 33. Detach turbo to intercooler hose
> 34. Detach turbo from manifold & remove
<---34a. Disregard this step. Remove the head with turbo as one unit.
> 35. Detach accelerator cable
<---35a. Detach cruise control rod and actuator. Tie them up to firewall.
> 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
<---39a. Disregard this step. Remove the head with the inlet manifold as one
unit.
> 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.

Note:
DO NOT REUSE HEAD BOLTS! THEY ARE STRETCHED.

This procedure does not include valve removal  and lapping, guide and seal
replacement, head decking, lifter checking etc. etc.

-- 
Igor Kessel
Two turbo quattros