volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Preparing cylinder head gasket for assembly > < Removing

Golf Mk5

Installing
Installing
–  Carefully remove metal particles, emery residue and cloths.
If the piston for No. 1 cylinder is not at TDC:
   
–  Turn crankshaft on the vibration damper securing bolt in direction of engine rotation to TDC No. 1 cylinder marking -arrow- while a second mechanic guides camshaft timing chain by hand.
  Note
t  Do not remove new cylinder head gasket from its packing until immediately before installing.
t  Handle new gasket with extreme care. Damage will cause leakage.
  N13-0475
–  Apply a 2 mm thick bead of sealant -D 176 501 A1- onto joint between cylinder block and sealing flange as shown -arrows-.
–  Immediately fit new cylinder head gasket. Inscription (Part No.) must be readable.
–  Additionally insert a little sealant -D 176 501 A1- into the two 3 mm holes in the cylinder head gasket, which lie on the sealant bead.
  N15-10214
–  Ensure that dowel sleeves are inserted into cylinder block holes 12 and 20, and that cylinder head gasket is located.
–  Position camshafts in cylinder head to TDC No. 1 cylinder.
  N15-0322
–  The camshaft bar -T10068 A- must engage in grooves in both shafts.
–  Fit cylinder head, screw in new cylinder head bolts and tighten hand tight.
  Note
The longer cylinder head bolts must be inserted in the centre holes of cylinder head.
  N15-10106
–  Tighten cylinder head bolts in tightening sequence shown working from inside to outside:
–  Pre-tighten all bolts to 30 Nm.
–  Then tighten all bolts to 50 Nm.
–  Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
–  Then tighten all bolts again 1/4 turn (90°) further.
Further assembly is basically the reverse of the dismantling sequence.
  Note
Ensure that the O-ring for sealing the oil channel and the seal are fitted in the cover.
–  Install camshaft adjuster with camshaft timing chain → Chapter.
–  Install cylinder head cover and intake manifold → Chapter.
–  Fill with new coolant → Chapter.
  Note
It is not necessary to retighten cylinder head bolts after repairs.
  N15-0322

Preparing cylinder head gasket for assembly > < Removing