Volkswagen Workshop Service and Repair Manuals

Checking compressions

Notes:

• ◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between bucket tappet and cam must be oiled after installation.
• ◆ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.
• ◆ When replacing the cylinder head the complete coolant must be renewed.

• Expanding clip
• Toothed belt guard - upper part

• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 13-19
• 45 Nm
• Camshaft sprocket
• ◆ Drive off camshaft taper using hammer and drift through toothed belt guard openings
• 10 Nm
• Rear toothed belt guard
• Cylinder head cover
• Cap
• ◆ Renew seal if damaged

• Upper sealing washer
• ◆ Renew if damaged
• Dished washer
• Cap
• To intake hose
• Retaining clip
• Pressure regulating valve
• ◆ For crankcase breather
• Gasket
• ◆ Renew if damaged
• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ Insert projections into holes on cylinder head
• Crankcase breather

• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-9 , removing and installing cylinder head
• Securing clip
• O-ring
• ◆ Renew
• Lower sealing cone
• Injector pipes
• ◆ Tighten to 25 Nm
• ◆ Remove with 3035
• ◆ Always remove pipework complete
• ◆ Do not alter shape
• Cylinder head
• ◆ Check for distortion => Fig. 1
• ◆ Removing and installing
  => Page 15-9
• ◆ If replaced renew the complete
  coolant

• Injector
• ◆ Removing and installing for engine codes 1Z, AHU, AEY, AFN, AVG ALE

=> Repair group 23; Servicing Diesel direct system; Removing and installing injectors

• ◆ Removing and installing for engine codes: 1Y, AAZ

=> Repair group 23; Servicing fuel injection system; Removing and installing injectors

• Glow plug
• ◆ For engine codes 1Z, AHU, AEY, AFN, AVG, ALE tighten to 15 Nm
  for engine codes 1Y, AAZ tighten to 25 Nm
• ◆ Checking

=> Repair group 28; Checking glow plug system; Checking glow plugs

• Lifting eye
• Cylinder head gasket
• ◆ Renew
• ◆ 11.93 ▸metal cylinder head gasket
• ◆ For vehicles ▸ 10.93 with soft material cylinder head gasket. In cases of repair install a new metal cylinder head gasket and replace swirl chambers => Page 15-35
• ◆ Note marking
  =>Fig. 2
• ◆ If replaced renew the complete
  coolant
• 20 Nm
• Idler roller
• ◆ Engine codes:
  1Z, AHU, AEY, AFN, AVG, ALE
• 25 Nm

• Tensioning roller
• ◆ The semi-automatic tensioning roller is illustrated
• ◆ Checking semi-automatic toothed belt tensioning roller
  => Page 13-31
• Eccentric
• ◆ For semi-automatic tensioning roller
• 45 Nm
• ◆ 20 Nm for semi-automatic tensioning roller

→ Fig. 1     Checking cylinder head for distortion

Max. permissible distortion: 0.1 mm

Note:

Reworking diesel cylinder heads is not permissible.

→ Fig.2     Cylinder head gasket identification

• ◆ Part No. = black arrow
• ◆ Holes/notches = white arrow

Note:

Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When replacing the cylinder head gasket, install a new gasket with the same identification.