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Dismantling and assembling intake pipes > < Piston and cylinder dimensions

Leon Mk2

Removing and installing cylinder head
Removing and installing cylinder head
Checking compressions → Chapter.
  Note!
t  When installing an exchange cylinder head with fitted camshaft, the contact surfaces between the bucket tappets and the cam must be oiled before installing the cylinder head cover.
t  The plastic packing pieces for protecting the open valves must not be removed until immediately before fitting cylinder head.
t  If the cylinder head is replaced, all the coolant in the system must also be renewed.
   
1 - Expanding clip
2 - Toothed belt guard - upper part
3 - Toothed belt
q   Mark D.O.R. before removing
q   Check for wear
q   Do not kink
q   Removing, installing and tensioning → Chapter
4 - 45 Nm
q   Use counter-hold -T20018- to loosen and tighten
5 - Camshaft sprocket
q   Drive off camshaft taper with a blow of a hammer on a drift (6 mm Ø) positioned through toothed belt guard openings
6 - 10 Nm
7 - Rear toothed belt guard
8 - Cylinder head cover
9 - Cap
q   Renew seal if damaged
10 - Upper sealing washer
q   Renew if damaged
11 - Dished washer
12 - Cap
13 - Connecting pipe
14 - Gasket
q   Renew if damaged
15 - Lower sealing cone
16 - Cylinder head cover gasket
q   Renew if damaged
q   Insert projections into holes on cylinder head
q   Before fitting gasket coat transition between bearing cap/cylinder head with -D2-
17 - Intake pipes cover
q   Dismantling and assembling → Chapter
18 - Cylinder head bolt
q   Renew
q   Note sequence when loosening and tightening → Chapter, Removing and installing cylinder head
19 - Intake pipes
q   Dismantling and assembling → Chapter
20 - Injector pipes
q   Tighten to 25 Nm
q   Remove and install with spanner -U-40072-
q   Always remove pipework complete
q   Do not alter shape
21 - Cylinder head
q   Check for distortion → Fig.
q   Removing and installing → Chapter
q   If replaced, renew the complete coolant
22 - Injector
q   Removing and installing: → Chapter
q   Servicing: → Chapter
23 - Glow plug, 15 Nm
q   Remove and install with spanner -U-40082-
q   Checking: → Chapter
24 - Cylinder head gasket
q   Renew
q   Note marking → Fig.
q   If replaced renew the complete coolant
25 - Lifting eye
26 - 20 Nm
27 - Tensioning roller
q   Checking semi-automatic toothed belt tensioning roller → Chapter
q   Tensioning toothed belt → Chapter, Removing, installing and tensioning toothed belt
28 - Idler roller
29 - 20 Nm

   
Checking cylinder head for distortion
Special tools and workshop equipment required
t  Feeler gauge
t  Straight edge
Test sequence
Max. permissible distortion: 0.1 mm
  Note!
Reworking diesel cylinder heads is not permissible.
  E15-0031
Cylinder head gasket identification
t  Part No. = arrow -1-
t  Production control code = arrow -2- (can be disregarded)
t  Holes = arrow -3-
  Note!
Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When replacing the cylinder head gasket, install a new gasket with the same identification.
  A15-0105

Dismantling and assembling intake pipes > < Piston and cylinder dimensions