Removing
Disconnect the wires from the battery.
Drain the coolant into a container.
For suction diesel engines, remove the air filter cover and filter element.
For a turbodiesel engine, remove the air filter housing and intake.
Remove valve cover.
Remove the injection pipes and lay them out on a clean surface.
Plug connections at injectors and fuel pump.
Remove the drain pipe from the injectors to the pump.
Disconnect wires from glow plugs.
Mark and remove the wire leading to the oil pressure sensor and to the temperature sensors.
Remove exhaust pipe.
Remove toothed belt.
Remove the coolant hoses from the cylinder head.
Disconnect the oil lines to the turbocharger and the line to the fuel pump.
Swing the cold start accelerator rod to the side or hang it up.
Remove cylinder head bolts in reverse order (compared to that shown in Fig.).
In order for the cylinder head to fit absolutely flat and evenly, the ten head screws must be tightened in the sequence shown in the figure. The tables below show the torques and angles of rotation to be observed when tightening the bolts
Remove cylinder head.
Installation
Correctly determine the thickness of the cylinder head seal (see next section).
Check the cylinder head joint surface for distortion. To do this, lay a long metal ruler or an absolutely straight metal square along the cleaned surface of the cylinder head. Using a feeler gauge, measure the deflection. The maximum allowable deflection is 0.1 mm. Firm "Volkswagen" does not recommend additional grinding of the cylinder head. Therefore, with a more significant deflection, the head must be urgently changed.
Clean the joint surface of the engine block.
Clean the threads of the holes in the engine block. The holes must be free of dirt, oil and water. Blow out with air.
Insert the cylinder head gasket into the engine block.
Place the cylinder head on the engine. First, loosely tighten all the bolts so that the gasket can be centered.
With a cold engine, tighten the cylinder head bolts according to the tightening diagram (see fig.), observing the tightening torques prescribed for your machine (see table).
In the first stages of tightening, the cylinder head bolts are tightened with a dynamometer wrench. At the next steps, tightening is carried out (depending on screw version) with observance of the angle of rotation with a hard key (see arrow) or again with a key with a dynamometer (see tables). | This will not work! For an additional measurement of the piston protrusion, a sliding gauge or caliper is too inaccurate. Should be measured with an indicator or micrometer. |
Perform further assembly (reassembly is done in the reverse order of disassembly).
After driving 1000 km, do not forget to additionally tighten the threads of the cylinder head screws!
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