Volkswagen Workshop Service and Repair Manuals

Checking compressions

Notes:

• ◆ 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.
• ◆ All bearing and running surfaces must be oiled before assembly.
• ◆ The plastic packing pieces for protecting the open valves must not be removed until immediately before fitting cylinder head.
• ◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.

• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 15-10
• 10 Nm
• 25 Nm
• 100 Nm
• Camshaft sprocket
• Hub
• ◆ With sender wheel
• ◆ Counter-hold with T10052 to loosen and tighten
• ◆ To remove, use puller T10052
• ◆ Removing and installing => Page 15-47, Removing and installing camshaft

• Rear toothed belt guard
• Sealing grommet
• ◆ Renew if damaged
• Hall sender (G40)
• ◆ For camshaft position
• ◆ To remove, remove sealing grommet item 9 from toothed belt guard
• ◆ Checking:

=> Repair group 23; Servicing diesel direct injection system; Checking Hall sender for camshaft position

• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-21, removing and installing cylinder head
• ◆ Before installing, set washers in cylinder head => Page 15-30 item 4, Servicing valve gear

• Pin 10 Nm
• ◆ For engine cover
• Cylinder head cover
• ◆ With oil filler neck
• ◆ Replace oil filler neck also if cylinder head cover is damaged
• ◆ Before fitting, thoroughly clean sealing surface of cylinder head with clean rag
• To turbocharger
• 10 Nm
• ◆ First hand tighten all bolts
• ◆ Then first tighten both top bolts and the rest from inside to outside diagonally to specified tightening torque

• Pressure regulating valve
• ◆ For crankcase breather
• Oil filler neck
• ◆ Renew
• Cap
• ◆ Renew seal if damaged
• Gasket
• ◆ Renew if damaged
• Bracket
• ◆ With fuel pipe/hose
• Cylinder head cover gasket
• ◆ Renew if damaged
• 20 Nm
• Lifting eye

• Unit injector
• ◆ Removing and installing

=> Repair group 23; Servicing diesel direct injection system; Removing and installing unit injectors

• Central connector
• ◆ For unit injector
• From brake servo
• Tandem pump
• ◆ For fuel and vacuum supply
• ◆ Removing and installing
  => Page 20-36
• ◆ Checking => Page 20-32
• Supply hose
• ◆ From fuel filter
  => Page 20-8
• ◆ White or with white marking
• ◆ Check securely seated
• ◆ Secure with spring-type clips

• Return hose
• ◆ To fuel filter
  => Page 20-8
• ◆ Blue or with blue marking
• ◆ Check securely seated
• ◆ Secure with spring-type clips
• Gasket
• ◆ Renew
• Bracket
• Tapered hexagon nut
• Cylinder head
• ◆ Removing and installing
  => Page 15-21
• ◆ If replaced renew the complete
  coolant

• Cylinder head gasket
• ◆ Renew
• ◆ Note marking
  =>Fig. 2
• ◆ If replaced renew the complete
  coolant
• Glow plug
• ◆ 15 Nm
• ◆ Checking

=> Repair group 28; Checking glow plug system; Checking glow plugs

• Tensioning roller
• 20 Nm + 1/8 turn (45 °) further

→ Fig. 1    Checking cylinder head for distortion

Max. permissible distortion: 0.1 mm

Note:

Reworking diesel cylinder heads is not permissible.

→ Fig.2    Cylinder head gasket identification

• ◆ Part No. = arrow 1
• ◆ Production control code = arrow 2 (can be disregarded)
• ◆ Holes = arrow 3

Note:

Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When replacing the cylinder head gasket, install a new gasket with the same identification.