volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Checking compression > < Removing

Golf Mk5

Installing
Installing
  Note
t  Always renew cylinder head bolts.
t  In cases of repair carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long scores or scratches are created. When using abrasive paper do not use a grade less than 100.
t  Carefully remove remains of emery and abrasives.
t  Remove new cylinder head gasket from packaging, just before installation.
t  Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.
–  Turn crankshaft to TDC marking before fitting cylinder head.
–  Turn crankshaft opposite engine direction of rotation until all pistons are approximately equally placed below TDC.
–  Fit cylinder head gasket.
  Note
Note identification on cylinder head gasket → Fig..
–  Fit cylinder head and tighten all cylinder head bolts hand-tight.
   
–  Tighten cylinder head in four stages in sequence as shown as follows:
1 - Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2 - Turn further with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
  Note
Later retightening of cylinder head bolts is not necessary after repairs.
Further installation is carried out in the reverse sequence of removal. When doing this, note the following:
  V15-0738
–  After tightening cylinder head, turn camshaft so that cams for No. 1 cylinder equally point upwards. Before fitting toothed belt, turn crankshaft in engine D.O.R. → Chapter, Removing, installing and tightening toothed belt.
–  Install hub for camshaft toothed belt pulley → Chapter, Removing and installing camshaft.
–  Install toothed belt → Chapter.
–  Install poly V-belt → Chapter.
–  Install sound insulation tray → General body repairs, exterior; Rep. Gr.50.
–  Install plenum chamber bulkhead → General body repairs, exterior; Rep. Gr.50.
–  Fill coolant system with coolant → Chapter.
–  Carry out road test and then read fault memory → Chapter.
  A15-0530

Checking compression > < Removing