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Assembly overview - intake manifold > < Piston and cylinder dimensions

Golf Mk4

Assembly overview - Cylinder head
Assembly overview - Cylinder head
Checking compression. → Chapter
  Note
t  When installing an exchange cylinder head with fitted camshaft, the contact surfaces between the bucket tappets and the cam must be oiled before installing the cylinder head cover.
t  The plastic packing pieces for protecting the open valves must not be removed until immediately before fitting cylinder head.
t  If the cylinder head is renewed, the entire coolant must also be renewed.
   
1 - Toothed belt guard - upper part
2 - Toothed belt
q   Mark direction of rotation before removing.
q   Check for wear.
q   Do not kink.
q   Removing, installing and tensioning → Chapter.
3 - 20 Nm
4 - 20 Nm
5 - 45 Nm
6 - Camshaft pulley
q   Pull off using two arm puller -T40001-
7 - Tensioning roller
q   Checking semi-automatic toothed belt tensioner → Chapter
8 - Idler roller
9 - Rear toothed belt guard
10 - 10 Nm
11 - Lifting eye
12 - Cylinder head bolt
q   Renew.
q   Note sequence when loosening and tightening → Chapter, Removing and installing cylinder head.
13 - Oil deflector
14 - Cylinder head cover
q   With vulcanised seal
15 - Seal
q   Renew if damaged.
16 - Cap
q   Renew seal if damaged.
17 - Breather pipe
18 - Retaining clip
19 - Pressure regulating valve
q   For crankcase ventilation.
20 - Gasket
q   Renew if damaged.
21 - 5 Nm
q   Only engine codes AGR, AHF, ALH, ASV
22 - Injector lines
q   Tighten to 25 Nm.
q   Remove using 3035
q   Always remove pipework complete
q   Do not alter bends
23 - Vacuum pump
q   For brake servo
24 - Gasket
q   Renew
25 - Injector
q   Removing and installing → Rep. Gr.23.
26 - Glow plug
q   15 Nm
q   Checking → Rep. Gr.28.
27 - Cylinder head gasket
q   Renew
q   Note marking → Fig.
q   After renewing, renew entire coolant.

   
Checking cylinder head for distortion
Max. permissible distortion: 0.1 mm.
  Note
Reworking diesel cylinder heads is not permissible.
  V15-0673
Cylinder head gasket identification
t  Part No. = arrow 1
t  Production control code = arrow 2 (can be disregarded)
t  Holes = arrow 3
  Note
Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When fitting a new cylinder head gasket, install a new gasket with same identification.
  A15-0105

Assembly overview - intake manifold > < Piston and cylinder dimensions