Volkswagen Workshop Service and Repair Manuals

Checking compressions

Notes:

• ◆ When installing an exchange cylinder head 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.

Engine codes AEK, ATU, AWF, AWG

• Pressure regulating valve
• ◆ For crankcase breather
• Plug

• 20 Nm
• Intake manifold - upper part
• ◆ Engine codes ATU, AWF, AWG:
  with throttle valve control part
• Gasket
• ◆ Renew
• Cap
• ◆ Renew seal if damaged
• 10 Nm
• Cylinder head cover
• Reinforcement strip
• Oil deflector
• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-9 , removing and installing cylinder head

• Cylinder head cover gasket
• ◆ Renew if damaged
• Cylinder head
• ◆ Check for distortion => Fig. 1
• ◆ Removing and installing => Page 15-9
• ◆ After replacing renew the complete coolant
• Cylinder head gasket
• ◆ Renew
• ◆ After replacing renew the complete coolant
• Camshaft sprocket
• ◆ Note position when installing the toothed belt
  => Page 13-20 , removing, installing and tensioning toothed belt
• Lifting eye
• Rear toothed belt guard
• 20 Nm

• Toothed belt
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing and installing
  => Page 13-20
• Tensioner
• Tensioning device for toothed belt
• ◆ Engine codes ATU, AWF, AWG
• 10 Nm
• ◆ Engine codes ATU, AWF, AWG
• 45 Nm
• Tensioner
• Toothed belt guard - upper part
• Toothed belt guard
• From the crankcase breather
• ◆  , Item 13

Engine codes AFT, AKS

• Connection piece
• 20 Nm
• Intake manifold - upper part
• Gasket
• ◆ Renew
• Cap
• ◆ Renew seal if damaged
• 10 Nm
• Cylinder head cover
• Reinforcement strip
• Oil deflector
• Cylinder head bolt
• ◆ Sequence when loosening and tightening => Page 15-9 , Removing and installing cylinder head

• Cylinder head cover gasket
• ◆ Renew if damaged
• Cylinder head
• ◆ Check for distortion
  => Page 15-8 , Fig.1
• ◆ Installing => Page 15-9
• ◆ After replacing renew the complete coolant
• Cylinder head gasket
• ◆ Renew
• ◆ After replacing renew the complete coolant
• Camshaft sprocket
• ◆ Note position when installing the toothed belt
  => Page 13-20 , removing, installing and tensioning toothed belt
• Lifting eye
• Rear toothed belt guard

• Toothed belt
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing and installing
  => Page 13-20
• Tensioner
• 45 Nm
• Toothed belt guard - upper part
• Toothed belt guard
• From the crankcase breather
• ◆  , Item 13

→ Fig. 1     Checking cylinder head for distortion

Max. permissible distortion: 0.1 mm

→ Fig. 2     Cylinder head bolts identifying features

A - Bolt with smooth head

• ◆ For previous cylinder head gasket

B - Bolt with raised portions on bolt head
-arrows-

• ◆ For metal cylinder head gasket