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Volkswagen Workshop Service and Repair Manuals

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Head cover - remove and install > < Piston and cylinder measures

Polo Mk4

Head - disassembly and assembly
Head - disassembly and assembly
  Note
t  To install an overhauled head, with the valve command shaft assembly, it is necessary to lubrificate the contact surfaces between tapped and eccentric, before installation of head covers.
t  The plastic bases, supplied to protect open valves, can only be removed immediately before head installation.
t  To replace head it is also necessary to fully replace the cooling fluid.
Check compression → Chapter.
   
1 - Upper cover from mechanical distribution
2 - Indented belt
q   Before removal, note down direction of rotation
q   Check wear
q   Do not fold
q   Remove and install, adjust → Chapter.
3 - 10 Nm
q   Replace
4 - 25 Nm
5 - 100 Nm
6 - Valve command shaft gear
7 - Cube
q   With rotation sensor.
q   To tighten and loosen, use the support -T10051-
q   To remove use pulling device -T10052-
q   Remove and install → Chapter, remove and install valve command shaft
8 - Rear cover from mechanical distribution
9 - Sealing scoop
q   Replace when damaged
10 - Sensor Hall -G40-
q   For the valve command shaft position
q   For removal take out sealing scoop → Item on the rear of mechanical distribution protector
11 - Head screw
q   Observe sequence when loosing and tightening → Chapter, Remove and install head
q   before assembly place washers on the head → Item, → Item
12 - Head cover
q   Before installation, carefully clean head sealing surface with a clean cloth
13 - Pressure regulator valve
q   For carter vent device
14 - To the turbo-compressor
15 - Container cover
q   Replace joint if damaged
16 - Sealing scoop
q   Replace when damaged
17 - 10 Nm
q   Observe tightening sequence → Chapter, Head cover - remove and install
18 - Head cover joint
q   Replace when damaged
q   Before placing seal transitions with “AMV 174 004 01” → Chapter, Head cover - remove and install
19 - 20 Nm
20 - Suspension eyelet
21 - Unit-pump-injector
q   Remove and install → Chapter.
22 - 10 Nm
23 - -Central connection
q   For unit - pump -injector
24 - From power brake
25 - Vacuum pump
q   To power brake
q   Check → Chapter.
q   Remove and install → Chapter.
26 - Supply hose
q   From fuel filter. → Chapter, → Item
q   White or with white marking
q   Ensure firm fixing
q   Ensure with spring clamps
27 - Return hose
q   To fuel filter → Chapter, → Item
q   Blue or blue marking, respectively
q   Ensure firm fixing
q   Ensure with spring clamps
28 - Joint
q   Replace
29 - Screw
30 - Head
q   Remove and install → Chapter.
q   After replacement, fully replace cooling fluid
31 - Head joint
q   Replace
q   Verify identification → Fig.
q   After replacing, fully replace cooling fluid
32 - Glower plug
q   15 Nm
q   Check → Chapter.
33 - Tension pulley
34 - 20 Nm + 45 °

   
Check if head is bent
Special tools and workshop equipment required
t  Auxiliary ruler
t  Razor gauge
Maximum permissible bending: 0.1 mm
  Note
Grinding of diesel engine heads is not permitted.
  V15-0673
Head joint-Identification
t  Number of replacement parts = -arrow 1-
t  Tax code = -arrow 2- (not important!)
t  Holes = -arrow 3-
  Note
Depending on piston projection, joints with different thickness may be installed. For joint replacement, install joint with the same identification.
  A15-0105

Head cover - remove and install > < Piston and cylinder measures