volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Indented belt - remove and install, adjust > < Piston and cylinder measures

Polo Mk4

Head - disassemble and assemble
Head - disassemble and assemble
Check compression → Chapter.
  Note
t  To install a used head with valve command shaft installed, it is necessary to lubricate contact surfaces between taps and eccentrics, before installation of head cover.
t  Plastic bases supplied to protect open valves may only be removed immediatley before installing engine head.
t  When replacing engine head it is necessary to replace all cooling fluid.
   
1 - Head joint
q   Replace
q   Observe identification → Fig.
q   After replacing, completely renew cooling fluid
2 - 20 Nm
3 - Engine head
q   Check bending → Fig.
q   Remove and install → Chapter.
q   After replacing, completely renew cooling fluid
4 - Suspension eyelet
5 - 8 Nm
q   For engine cover
6 - Head fastening screw
q   Replace
q   Observe installation and removal sequence → Chapter, remove and install head
7 - Oil deflector
8 - Head cover
q   With vulcanized seal
9 - Sealing ring
q   Replace when damaged
10 - Container cover
q   Replace joint if damaged
11 - Vent tube
12 - Braces
13 - Pressure regulating valve
q   For carter ventilation device
14 - Joint
q   Replace when damaged
15 - 10 Nm
16 - Injection tubes
q   Tighten screw at 25 Nm.
q   Remove with star wrench 3035
q   Always remove complete tube set
q   Do not change bending
17 - Support
q   For engine cover
18 - 20 Nm
19 - Vacuum pump
q   For servo-brake
20 - 20 Nm
21 - Joint
q   Replace

   
Check head bending
Special tools and workshop equipment required
t  Razor gauge
t  Auxiliary rule
Checking sequence
Maximum permissible bending: 0.1 mm
  Note
Diesel engine head grinding is not permitted.
  N15-0302
Head joint-Identification
t  Replacement part number = -arrow 1-
t  Tax code = -arrow 2- (not important!)
t  Holes = -arrow 3-
  Note
Depending on piston protuberance joints with different thickness may be installed. To replace joint, install joint with same identification.
  A15-0105

Indented belt - remove and install, adjust > < Piston and cylinder measures