Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 3268 Camshaft bar
• ◆ 3273 Retainer
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)
• ◆ AMV 188 001 02
• ◆ AMV 174 004 01

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.

• 5 Nm
• H.T. cable guide
• 25 Nm

• Rear right support
• ◆ Between intake manifold upper part and cylinder head
• ◆ With bracket for fuel pipes
• Bracket
• ◆ For fuel pipes
• Flame trap coil
• Circlip
• Cap
• ◆ Renew seal if damaged
• 10 Nm
• Bracket
• ◆ For electric wires
• Cylinder head cover
• ◆ Removing and installing
  => Page 15-9

• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ Note fitting position
• O-Ring
• ◆ Renew
• ◆ Oil before fitting and insert in the camshaft sprocket cover Pos. 21
• Spacer ring
• O-ring
• ◆ Renew
• ◆ Oil before installing
• Hall sender (G40)
• ◆ On vehicles 01.93 ▸
• ◆ On vehicles ▸ 12.92 in distributor
• ◆ Checking:

=> Repair Group 01; Self-diagnosis; Interrogating fault memory

• Bracket
• ◆ For 42-pin connector and pump for continued coolant circulation

• Ignition transformer (N152)
• ◆ On vehicles 01.93 ▸
• ◆ On vehicles ▸ 12.92 distributor
• ◆ Checking:

=> Repair Group 01; Self-diagnosis; Interrogating fault memory

• Chain tensioner, 30 Nm
• ◆ For double chain
• ◆ Bleed before installing
  , Fig. 3
• ◆ From engine number:
  AAA 217001 or ABV021781
  without bleeder hole
• ◆ Only turn engine with chain tensioner installed
• Seal
• ◆ Renew
• Camshaft sprocket cover
• ◆ Coat sealing surfaces with AMV 188 001 02
• ◆ If only the camshaft sprocket cover has been removed, prepare cylinder head gasket for assembly
  => Fig. 2

• Cylinder head gasket
• ◆ Renew
• ◆ If replaced renew the complete
  coolant
• Cylinder head
• ◆ Check for distortion => Fig. 1
• ◆ Installing => Page 15-12
• ◆ If replaced renew the complete
  coolant
• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-12 , installing cylinder head
• Intake manifold lower part gasket
• ◆ Renew
• Lifting eye
• Intake manifold - lower part

• Ribbed belt tensioner
• ◆ Removing and installing ribbed belt => Page 13-22
• Intake manifold upper part gasket
• ◆ Renew
• Intake manifold upper part
• ◆ First tighten to intake manifold lower part, then tighten both rear supports, Pos. 4 and 32
• Intake manifold temperature sender (G72), 10 Nm
• ◆ Checking:

=> Repair Group 01; Self-diagnosis; Interrogating fault memory

• Rear left support
• ◆ Between intake manifold upper part and cylinder head
• ◆ With engine earth connection
• Cover
• ◆ Above intake manifold upper part

→ Fig. 1     Checking cylinder head for distortion

Max. permissible distortion: 0.1 mm

→ Fig.2     Preparing cylinder head gasket for assembly

• ‒ Remove old sealant from 3 mm holes in the cylinder head gasket -arrows-.
• ‒ Fill 3 mm holes in the cylinder head gasket with sealant AMV 188 001 02.

Note:

With the cylinder head installed the holes are only half visible.