First time removing head - Troubleshooting - VWDiesel.net The IDI, TDI, and mTDI source.

• First time removing head by leprechan on 20 Jun, 2005 20:54
• Hey everyone,
  
  I recently blew a head gasket in my 1.6na jetta and I started to tear the top end apart, but I'm having a little trouble getting the head off.  I followed the bentley instructions to a T(or so I thought).  The bentley said nothing about taking the cam out so that is still attached, as well as the injection pump.  When I try to lift the head off the engine it hangs up on the rear timing belt cover around the injection pump.  Any suggestions from you expert vw mechanics would sure make life easier.  Thanks in advance.
  
  Nick
• #1 by watsongs on 20 Jun, 2005 21:56
• Well, I would start by taking off the cover.  I just removed my head last week, and took off all the overs so I could get the belt off - I'm not sure how you could get it off without it, but mine's a 1.5.  I also had a hell of a time with the manifolds - I ended up taking a sawzall to my resonator, which was rusted out anyway.  Now I'm dealing with worn valve guides and injection nozzles, but at least everything else looks ok.
• #2 by leprechan on 20 Jun, 2005 22:07
• The belt has already been removed.  What I called the cover is that thin metal plate that is behind the timing belt.  Did you have to remove the cam sprocket to remove your head?  If so, whats the best way to pry that thing off of there?
• #3 by watsongs on 21 Jun, 2005 00:44
• I did pull mine off, but it came off pretty easy witha gear puller I got in the bargain bin at Ace Hardware - no such luck on the IP pulley, though, I'm still working on that one.
• #4 by chrissev on 21 Jun, 2005 18:14
• Quote from: "leprechan"

  The belt has already been removed.  What I called the cover is that thin metal plate that is behind the timing belt.  Did you have to remove the cam sprocket to remove your head?  If so, whats the best way to pry that thing off of there?

  
  
  I believe the cam sprocket must come off, as the camshaft goes through a hole in the metal timing belt cover which, if you have not yet discovered, cannot be removed without first removing everything on that side of the engine including the injection pump.  The cam sprocket is removed with a puller.  It must be removed anyway before you put the timing belt back on in order to get the belt centered so you might as well do it now.  You need a fairly heavy duty puller for this job.  Someone once told me you could hit it off with a hammer...I did not see how when I did my belt, and also I think you would damage either the camshaft or the sprocket by doing this.
• #5 by fillmore on 28 Jun, 2005 18:25
• i used a pipe wrench and a hammer to get mine off