Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ V.A.G 1332 Torque wrench (40...200 Nm)
• ◆ Guide pins 3070

Installing

Notes:

• ◆ Always renew cylinder head bolts.
• ◆ In cases of repair carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long grooves or scratches are created. When using abrasive paper do not use a grade less than 100.
• ◆ Carefully remove emery and abrasive remains.
• ◆ Remove new cylinder head gasket from packaging, just before installation.
• ◆ Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.

• ‒ Turn crankshaft to TDC marking before fitting cylinder head.
• ‒ Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below TDC.
• ‒ Place cylinder head gasket on.

• ‒ → To centralize, screw guide pins from 3070 into the outer threaded holes on the intake side.
• ‒ Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
• ‒ Remove guide pins with removal tool from 3070 and install cylinder head bolts.

• ‒ → Tighten cylinder head in four stages in sequence shown as follows:
• ‒ 1. Tighten initially with torque wrench:
       Stage I = 40 Nm
       Stage II = 60 Nm
• ‒ 2. Turn further with normal spanner:
       Stage III = 1/4 turn (90 °)
       Stage IV = 1/4 turn (90 °)

Notes:

• ◆ Loosening cylinder head: Reverse sequence.
• ◆ Pulling-down cylinder head after repairs is not necessary.

• ‒ After tightening the cylinder head turn camshaft so that the cams for No. 1 cylinder point evenly upwards. Turn crankshaft, in engine D.O.R., To TDC before fitting toothed belt.