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.
• ◆ 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.

• Expanding clip
• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 15-11
• 45 Nm
• Camshaft sprocket
• ◆ Drive from camshaft taper using hammer and drift through hole in rear toothed belt guard => Page 15-11 , Removing, installing and tensioning toothed belt
• 10 Nm
• Rear toothed belt guard

• Cylinder head cover
• Cap
• ◆ Renew seal if damaged
• Upper sealing washer
• ◆ Renew if damaged
• ◆ Note fitting position
• Dished washer
• ◆ Note fitting position
• Cap
• ◆ Not present on all engines
• Connecting hose
• Gasket
• ◆ Renew if damaged
• Lower sealing cone
• ◆ Renew if damaged
• ◆ Note fitting position

• Cylinder head cover gasket
• ◆ Renew if damaged or leaking
• ◆ Note fitting position
• ◆ Insert projections into holes on cylinder head
• ◆ Before fitting gasket coat transition between bearing cap/cylinder head with "D2"
• Intake manifold cover
• ◆ Removing and installing
  => Page 15-9 , Removing and installing intake manifold
• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-27 , removing and installing cylinder head
• Intake manifold
• ◆ Removing and installing
  => Page 15-9

• Injector pipes
• ◆ Tighten to 25 Nm
• ◆ Remove with ring spanner 3035
• ◆ Always remove pipework complete
• ◆ Do not alter shape
• Cylinder head
• ◆ Check for distortion => Fig. 1
• ◆ Removing and installing
  => Page 15-27
• ◆ If replaced renew the complete
  coolant
• Injector
• ◆ Removing and installing for engine code AEF:

=> Repair group 23; Servicing fuel injection system; Removing and installing injectors

• ◆ Removing and installing for engine codes AGD, AHG, AKU, ASX:

=> Repair group 23; Servicing Diesel direct system; Removing and installing injectors

• Glow plug
• ◆ For engine codes AGD, AHG, AKU, ASX tighten to 15 Nm,
  for engine code AEF tighten to 25 Nm
• ◆ Checking:

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

• Cylinder head gasket
• ◆ Renew
• ◆ Note marking
  =>Fig. 2
• ◆ If replaced renew the complete
  coolant
• Lifting eye
• 20 Nm
• Tensioning roller
• ◆ Checking semi-automatic toothed belt tensioning roller => Page 13-14
• ◆ Tensioning toothed belt
  => Page 15-11 , Removing, installing and tensioning toothed belt

• Idler roller
• ◆ Only engine codes AGD, AHG, AKU, ASX
• 25 Nm

→ Fig. 1     Checking cylinder head for distortion

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Feeler gauge
• ◆ Straight edge

Test sequence

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.