Volkswagen Workshop Service and Repair Manuals

Assembly overview - cylinder head

1 -	Cylinder head gasket

q

Renew.

q	Cylinder head gasket identification → Fig..

q	Renew coolant and engine oil after replacing.

2 -

10 Nm

q	Insert with locking fluid, locking fluid → Electronic parts catalogue.

3 -	Hall sender -G40-

q	For camshaft position.

q	Removing and installing → Chapter

4 -	Cylinder head

q	Removing and installing → Chapter.

q	To prevent damage to glow plugs, always place cylinder head on a soft foam surface after removal.

q	Check for distortion → Fig..

q	Must not be reworked.

q	Before installing, check that the two dowel sleeves for centring cylinder head on cylinder block are fitted.

q	Renew coolant and engine oil after replacing.

5 -

Washer

6 -	Cylinder head bolt

q

Renew.

q	Sequence when loosening → Fig..

q	Specified torque and tightening sequence → Fig..

7 -	Oil pressure switch -F1-, 20 Nm

q	Switch pressure 0.3…0.6 bar

q	Removing and installing → Chapter.

q	Checking → Chapter.

8 -

Seal

q

Renew.

9 -

20 Nm

10 -	Engine lifting eye

11 -

Seal

q

Renew.

12 -

20 Nm

13 -

Gasket

q

Renew.

14 -	Vacuum pump

q	Removing and installing → Chapter.

15 -

10 Nm

16 -	Connection

q	For coolant hoses

q	With coolant temperature sender -G62-

17 -

9 Nm

18 -

Gasket

q

Renew.

19 -

20 Nm

20 -	Engine lifting eye

Observe sequence when loosening cylinder head bolts –  Slacken cylinder head bolts in the sequence -1 … 10-.

Checking cylinder head for distortion –  Use straight edge and feeler gauge to measure cylinder head for distortion at several points. l  Max. permissible distortion: 0.1 mm.   Note Cylinder heads for TDI engines must not be reworked.

Cylinder head gasket identification 1 -  Part number 2 -  Holes 3 -  Ignore   Note Different thicknesses of cylinder head gasket are fitted depending on the piston projection. If only cylinder head gasket is removed, install a new cylinder head gasket with same identification.

Cylinder head - specified torque and sequence   Note Renew bolts for cylinder head. –  Tighten bolts in 4 stages in the sequence shown:

Stage	Bolts	Specified torque/turning further angle
1.	-1 … 10-	30 Nm
2.	-1 … 10-	50 Nm
3.	-1 … 10-	Turn 90° further
4.	-1 … 10-	Turn 90° further