volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Compression - check > < Operation sequence

Polo Mk4

Installation
Installation
  Note
t  Remove the new engine cylinder head sealing gasket from the package immediately before installation only.
t  Handle the new gasket as carefully as possible. Damage may cause leaks.
–  Put a clean cloth on the cylinder so as to prevent any dirt or sandpaper residues from getting in between the cylinders and the pistons.
–  Also prevent dirt and sandpaper residues from getting into the cooling system.
–  Carefully clean engine cylinder head and cylinder block sealing surfaces. Make sure that no longitudinal scrapes or scratches are produced in this operation (when using sandpaper, the grain should never be lower than 100).
–  Carefully remove sandpaper residues with a cleaning cloth.
–  Place the cylinder 1 piston in TDC and turn the crankshaft slightly backwards.
   
–  To align the engine cylinder head, screw the Guide pins -3450/1- into the external rear holes of engine cylinder head bolts -arrows-.
–  Place the new cylinder head sealing gasket onto the centring pins -A-. The inscription (spare part number) must be legible.
  WARNING
Always replace self-locking nuts and screws subject to angular torque
–  Install the engine cylinder head and the 8 remaining new cylinder head bolts and tighten manually.
–  Loosen the Guide pins -3450/1- with the Puller -3450/3-, through the screw holes. For that, turn the Puller -3450/3- to the left until the pins are removed.
–  Install the two new remaining cylinder head bolts and tighten them manually.
  R15-0005
–  Tighten the new cylinder head bolts in the indicated tightening sequence, as follows:
–  Tighten them to 30 Nm.
–  Then, apply a 180° angle torque with a hard spanner.
  Note
There is no need to retighten the engine head screws after the repairs.
–  Continue installation in the reverse sequence to the removal.
  Note
When turning the camshaft, the crankshaft cannot be in TDC. Risk of damage to the piston crown/valves.
Installing the toothed belt and adjusting the distribution times → Chapter.
Replenish with new coolant → Chapter.
–  Consult the event memory → Chapter.
  V15-0738

Compression - check > < Operation sequence