Cylinder head assembly for 2.3-I-VR5 engine
- 1 - Upper intake manifold. The upper intake manifold is first attached to the lower intake manifold, and then the manifold assembly is attached to the cylinder head;
- 2 - throttle body;
- 3 - bolt, 10 Nm;
- 4 - lid;
- 5 - cylinder head cover. When installing the cover, a layer of sealant WV-D454300A3 must be applied to the segmented recess around the perimeter of the cover;
- 6 - bracket;
- 7 - bolt, 25 Nm;
- 8 - cylinder head mounting bolt. When installing, it is necessary to use new bolts and tighten the bolts in a certain sequence in several stages;
- 9 - cylinder head. If the flatness is more than 0.1 mm, it is necessary to regrind the cylinder head. The minimum permissible height of the cylinder head is 139.5 mm;
- 10 - Round sealing ring. When installing, it is necessary to use a new sealing ring lubricated with clean engine oil;
- 11 - timing chain cover. Removal and installation of the timing chain cover can only be performed on the installed cylinder head. When installing the timing chain cover, it is necessary to fill the holes in the end of the cover with liquid sealant VW-AMV18800102;
- 12 - chain tensioner, 40 Nm. The engine can only be turned with the chain tensioner installed;
- 13 - sealing ring;
- 14 - water pump;
- 15 - ignition system unit;
- 16 - thermostat housing;
- 17 - sealing ring. If the seal is broken, a new sealing ring must be used;
- 18 - Cylinder head gasket. A new cylinder head gasket must be used during installation;
- 19 - lower part of the intake manifold;
- 20 - Seal for the upper part of the intake manifold. If damaged, a new seal must be used;
- 21 - bolt, 5 Nm;
- 22 - combination valve;
- 23 - Seal for the lower part of the intake manifold. If damaged, a new seal must be used;
- 24 - V-belt tensioning mechanism;
- 25 - bolt, 5 Nm;
- 26 - bracket;
- 27 - vacuum actuator
Cylinder Head Bolt Tightening Sequence for VR5 Engine
The information is posted on this resource: VWmanual.ru
Warning: The operations for removing and installing the cylinder head on the VR5 engine are similar to the operations for removing and installing the cylinder head on a four-cylinder gasoline engine. This section only describes the differences for removing and installing the cylinder head on VR5 engines.
Execution order
1. Remove the cylinder head mountings and the cylinder head cover.
2. Unscrew the cylinder head mounting bolts in the reverse order of tightening them (see figure Cylinder head bolt tightening sequence on VR5 engine).
3. Clean the holes (indicated by arrows) 3 mm in diameter from the sealant at the end of the drive chain cover.
4. Fill the holes in the end of the timing chain cover with liquid sealant VW-AMV18800102.
Warning: After installing the cylinder head, the sealant holes in the end of the timing chain cover are half-closed.
5. Before installing the cylinder head gasket, check that holes 15 and 16 (see figure Cylinder head bolt tightening sequence on VR5 engine) guide bushings are installed on the cylinder block.
6. Carefully install the head onto the cylinder block. Insert and hand tighten the cylinder head bolts and washers.
7. In a certain sequence (see figure Cylinder head bolt tightening sequence on VR5 engine) tighten all bolts to a torque of 30 Nm, then tighten all bolts to a torque of 50 Nm and finally tighten all bolts in two stages, each time by 90°.
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