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Volkswagen Workshop Service and Repair Manuals

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Checking compression > < Removing

Golf Mk5

Installing
Installing
  Note
t  There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head.
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.
–  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 crankshaft has been turned in the meantime, position No. 1 cylinder piston to TDC and then turn crankshaft back slightly.
   
–  To centralize, screw guide pins -3450/2A- into front outer cylinder head bolt threaded holes.
  Note
The tolerance of the centring holes is reduced in the upper section. Therefore, before positioning cylinder head, check that guide pins can be removed upwards. If necessary, knurled part of guide pins may be ground off slightly.
–  Fit new cylinder head gasket.
–  Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
–  Remove guide pins with removal tool through bolt holes. To do this, turn removal tool anti-clockwise until pins are free.
–  Now insert last two cylinder head bolts and tighten them hand-tight also.
  N15-0208
–  Tighten cylinder head bolts in tightening sequence as follows:
–  Pre-tighten all bolts to 40 Nm.
–  Then tighten all bolts 1/4 turn (90 °) further using a rigid spanner.
–  Finally tighten all bolts again 1/4 turn (90 °) further.
Further assembly is basically the reverse of the dismantling procedure.
  Note
When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns.
Installing toothed belt and adjusting valve timing → Chapter.
–  Install poly V-belt tensioning element.
t  Torque setting: 25 Nm
–  Install poly V-belt → Chapter.
Filling with new coolant → Chapter.
  V15-0738

Checking compression > < Removing