volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Checking valve timing > < Removing

Golf Mk4

Installing
Installing
–  Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
–  Also prevent dirt and emery cloth particles from getting into coolant.
–  Now carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100).
–  Carefully remove metal particles, emery residue and cloths.
If piston of no. 1 cylinder is not at TDC:
   
–  Turn crankshaft in engine DOR at securing bolt of vibration damper to TDC no. 1 cylinder marking -arrow-.
  Note
t  Do not remove new cylinder head gasket from its packing until immediately before installing.
t  Handle new gasket with extreme care. Damage will cause leakage.
–  Fit new cylinder head gasket. Lettering (Part No.) must be readable.
  N13-0135
–  Ensure that dowel sleeves are inserted into cylinder block holes 15 and 16, and the cylinder head gasket is located.
–  Position camshafts in cylinder head at TDC no. 1 cylinder.
  N15-0164
–  Camshaft bar -3268- must engage in groove of long camshaft and align with shoulder of short camshaft.
–  Now prepare cylinder head gasket for assembly → Fig..
–  Fit cylinder head, screw in cylinder head bolts and tighten by hand.
  N15-0156
–  Tighten cylinder head bolts in tightening sequence as follows:
–  Pre-tighten all bolts to 30 Nm.
–  Then tighten all bolts to 50 Nm.
–  Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
–  Then tighten all bolts again 1/4 turn (90°) further.
Further assembly is basically the reverse of the dismantling procedure.
  Note
Ensure that O-ring for sealing oil channel in cover is installed.
Adjusting valve timing → Chapter.
Filling with new coolant → Chapter.
  Note
It is not necessary to retighten cylinder head bolts after repairs.
  N15-0164

Checking valve timing > < Removing