volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Checking compression > < Removing cylinder head
Installing cylinder head
Installing cylinder head
  Note
t  There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head.
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.
t  Renew cylinder head bolts.
Carry out the following work:
–  Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
–  Also prevent dirt and emery cloth particles from getting into coolant.
–  Carefully clean sealing surfaces of cylinder head and cylinder block. Ensure that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100).
–  Carefully remove metal particles, emery residue and cloths.
–  If crankshaft is turned in the meantime, position piston of No. 1 cylinder at TDC and turn crankshaft back slightly.
–  Position new cylinder head gasket; inscription (Part No.) must be legible.
   
–  Note centring pins in cylinder block -arrows-.
–  Fit cylinder head.
–  Insert cylinder head bolts and hand-tighten.
  A15-0135
–  Tighten cylinder head bolts in tightening sequence as follows:
  A15-0767
StageTighten
1
–  Tighten to 40 Nm using torque wrench.
2
–  Turn 90° (1/4 turn) further using rigid spanner.
3
–  Turn 90° (1/4 turn) further using rigid spanner.

–  Install cylinder head cover → Chapter.
–  Install toothed belt → Chapter.
Further assembly is basically the reverse of the dismantling sequence.
Fill with new coolant → Chapter.
   

Checking compression > < Removing cylinder head