Cylinder head — removal (VW Lt 28)

Removal the head

Repair of the cylinder head is possible without removing the engine from the car. To make operations easier, it is recommended to remove the seats.

• Remove the engine cover.
• Drain the coolant.
• Disconnect the battery.
• Remove the filter and the exhaust and intake manifolds.
• Disconnecting the glow plugs and injector wires.
• Disconnect all wires from the head.
• Remove the metal shields from the front and rear timing belts.
• Remove the head cover.
• Remove the outer disc of the vacuum pump belt pulley and remove the toothed belt.
• Remove the surge tank and place it with the wires on the side.
• Remove the air filter.

Caution! When tightening or loosening the bolts securing the camshaft and fuel pump drive gears, it is essential to lock the said gears using a special tool designated 3036 or a tool installed in such a way as to prevent excessive stretching of the timing belt.

Once the cylinder head is removed, it's recommended to set the No. 1 piston to TDC for ease of installation of the camshaft and fuel pump. The crankshaft must be rotated. For this purpose, you cannot use fan blades, which can break. You can turn the crankshaft with a screwdriver through the hole in the clutch housing. The marks on the fuel pump housing, on the engine housing and on the fuel pump gear ring must be in line, and the mark on the belt pulley must be opposite the mark on the clutch housing.

• Lock the fuel pump gear with a pin (diameter 15.5 mm, length 70 mm), which should be located in the gear hole and in the console.




Figure 2.10. Removing the rear camshaft gear: A - Special device for locking the fuel pump gear; B - Lever that grips the camshaft gear.


• Support the pump drive gear (the gear is mounted on the rear of the camshaft).
• Unscrew the bolt and remove the gear and timing belt.

Important! Please note that the rear camshaft gear is not installed using a key, despite the presence of a groove in the gear sleeve and a milling on the end of the shaft. Also, remember that both gears are the same on both the camshaft and the fuel pump. At the front of the engine, after unscrewing the side and bottom bolts, remove the lower air duct element.

• Remove the fan and air duct components.
• Remove the V-belt from the generator.
• Reduce timing belt tension. To do this, loosen the bolts securing the coolant pump, located in the housing on the left side of the front wall of the engine, and then lightly tighten the pump.
• Raise the front crankshaft gear using a special tool inserted into the gear hole.
• Loosen the gear mounting bolt on the front end of the camshaft by one turn.
• Use a puller or knock out the gear with a punch by hitting the gear sleeve.
• Remove the gear together with the timing belt.
• Unscrew the head mounting bolts. Remove the head. Despite the fact that it is made of light alloy, it is still quite heavy and when lifting it you need to use the services of an assistant.