Volkswagen Workshop Service and Repair Manuals

Installing   Note t  Always renew cylinder head bolts. t  In cases of repair, carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. When using abrasive paper do not use a grade less than 100. t  Carefully remove emery and abrasive remains. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. t  Exercise extreme caution. Ask a second mechanic for assistance. t  Guide the cylinder head in the timing belt guard.

t  When doing this, the cylinder head must not scrape over the dowel sleeves. –  Before fitting cylinder head, remove crankshaft stop -T10050- and turn crankshaft opposite direction of rotation until all pistons are nearly uniformly below TDC.

–  Unscrew Hall sender -G40--arrow-.

–  Note cylinder head gasket identification: 1 -  Part number 2 -  Holes 3 -  Ignore –  Cylinder head gasket must lie with identification facing upwards.

–  To centre, screw guide pins -3070/9- into outer threaded holes on intake side.   Note t  Golf, Golf Plus: The tensioning roller must be inserted on the pins when fitting the cylinder head. t  Polo: Belt tensioner must be pushed onto stud after fitting cylinder head. t  Polo: Support bonnet again. t  If the cylinder head gasket or cylinder head have been replaced, select the new cylinder head gasket according to the number of holes on the old cylinder head gasket. t  If parts of the crankshaft assembly have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at „TDC“ → Chapter. –  Fit cylinder head. –  Insert 8 cylinder head bolts and screw in to stop by hand. –  Unscrew guide pins -3070/9- through bolt holes in cylinder head and screw remaining cylinder head bolts by hand until contact is made.

–  Tighten cylinder head in four stages in sequence shown as follows: 1 -  Tighten initially with torque wrench: Stage I = 35 Nm Stage II = 60 Nm 2 -  Turn further with rigid spanner: Stage III = turn 90° further. Stage IV = turn 90° further.

–  Re-fit Hall sender -G40--arrow-. Golf, Golf Plus, Passat, Touran

–  Secure rear toothed belt guard -arrow- on cylinder head. Polo –  Secure rear toothed belt guard -arrow- on cylinder head after supporting it. Continuation for all vehicles: –  Install hub and camshaft pulley. –  Lock camshaft and high-pressure pump with diesel injection pump locking pin -3359-

–  Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop -T10050-. Further installation is carried out in the reverse order. In the process, note the following: Polo Support engine again → Chapter. –  Re-install toothed belt → Chapter. –  Installing engine support → Chapter. Continuation for all vehicles: –  Golf, Golf Plus, Passat, Touran: Re-install toothed belt → Chapter –  Install cylinder head cover → Chapter. –  Install oil supply line and turbocharger support → Chapter. –  Install poly V-belt → Chapter. –  Replenish coolant → Chapter. –  Top up engine oil → Chapter. After any work on the fuel system Connect a vehicle diagnostic tester. Perform the function „Filling/bleeding high pressure pump/fuel system“ in „Guided functions“ → Chapter. –  Carry out road test and read all event memories.