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Removing and installing the cylinder head, 1.8 litre engine > < Cylinder head

Leon Mk1

Cylinder head - Assembly overview, 1.8 litre engine
Cylinder head - Assembly overview, 1.8 litre engine
  Note
t  Replace the cylinder head cover bolts.
t  During assembly, renew oil seals and gaskets as well as self-locking nuts and bolts that are tightened by turning through to a specified angle.
t  The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.
t  When replacing the cylinder head or cylinder head gasket, the old coolant must also be replaced.
   
1 - Cylinder head gasket
q   Replace
q   Note the fitting position: The part number should point to the cylinder head
2 - Bolt.
q   25 Nm
3 - Transport plate
4 - Bolt.
q   Tightening sequence → Fig.
5 - Cylinder head
q   Removing and installing → Chapter
q   Check for deformation → Fig.
6 - Cylinder head bolt
q   Replace
q   Note correct sequence when loosening (1.8 ltr. engine) → Fig.
q   Note correct sequence when tightening (1.8 ltr. engine) → Fig.
7 - O ring
q   Replace
q   Lubricate with engine oil.
8 - Sealing plug
q   5 Nm
q   With ball head for engine cover panel
9 - Sealing plug
q   With gasket
10 - O ring
q   Replace
q   Lubricate with engine oil.
11 - Sealing plug
12 - To intake manifold
13 - Heat shield
14 - Bolt.
q   20 Nm
15 - Bolt.
q   20 Nm
16 - To intake manifold/turbocharger
17 - Breather pipe
18 - O ring
q   Not available as a separate replacement part
19 - Seal
q   Not available as a separate replacement part
20 - Engine cover panel
21 - Bolt.
q   Tightening sequence → Fig.
22 - Crankcase breather
q   Note correct sequence when tightening → Fig.
23 - Seal
q   Not available as a separate replacement part
24 - Seal
q   If this is damaged, replace it
25 - Vacuum pump
q   Removing and installing → Rep. gr.47
26 - Bolt.
q   Tightening torque → Rep. gr.47
27 - Joint mouth
28 - Bracket
29 - Bolt.
q   9 Nm
30 - O ring
q   Replace
q   Lubricate with coolant
31 - Transport plate
32 - Bolt.
q   25 Nm
33 - Bolt.
q   9 Nm
34 - Hall sender -G40-
35 - Separating plate

   
Crankcase breather system - tightening torque
  Note
t  The bolts are thread-forming bolts. When renewing the cylinder head, it is important that you use only genuine bolts since the cylinder head is supplied without threaded holes for attachment of the crankcase breather.
t  Do NOT make threaded holes using a thread tap.
–  Tighten bolts for crankcase breather system in the sequence -1 ... 10- to 11 Nm.
  A15-10605
Slackening cylinder head 1.8 ltr. engine
–  Unscrew bolts -arrows-.
–  Slacken cylinder head bolts in the sequence -1 ... 5-.
  A15-10474
Cylinder head - tightening sequence 1.8 ltr. engine
–  Tighten cylinder head bolts in the sequence -1 ... 5- as follows:
1.  Tighten with torque wrench initially to 40 Nm.
2.  Use fixed wrench to turn 90° further.
3.  Use fixed wrench to turn 90° further.
4.  Pre-tighten bolts -arrows- to 8 Nm.
5.  Turn bolts -arrows- 90° further using a rigid wrench.
  A15-10475
Checking cylinder head for distortion
–  Use straight edge and feeler gauge to measure cylinder head for distortion at several points.
t  Maximum permissible deformation: 0.05 mm
  V15-0654

Removing and installing the cylinder head, 1.8 litre engine > < Cylinder head