Tightening sequence of cylinder head bolts on a four-cylinder engine 1.8-I, AGN/AGU
- stage 1 - 40 Nm;
- stage 2 - 60 Nm;
- stage 3 - turn to 90° angle;
- stage 4 - turn to 90° angle
Tightening sequence of cylinder head bolts on a four-cylinder engine 1.6-I, AEH/AKL
- stage 1 - 40 Nm;
- stage 2 - turn to 90° angle;
- stage 3 - turn to 90° angle
Execution order
1. To properly install the cylinder head and cylinder head gasket, screw the VW-3070 guide pins into the outer hole of the cylinder block intended for the cylinder head mounting bolts.
2. If you don't have the guide pins, you can make your own by using two old cylinder head bolts. Cut off the head bolts and cut a slot for the screwdriver instead. After installing the cylinder head, use the screwdriver to unscrew the guide pins.
Warning: When installing the cylinder head, a new gasket must be used. Remove the gasket from its sealed packaging immediately before installing it on the cylinder block.
3. Check that the new cylinder head gasket is the same type as the original and that the TOP or OBEN marking is facing upwards. Position the new cylinder head gasket on the cylinder block surface on the guide pins. Check that the holes are correctly aligned with the cooling and lubrication system passages.
4. Carefully install the head onto the cylinder block.
5. Insert and hand tighten the 8 cylinder head bolts and washers.
6. Use a screwdriver to unscrew the two guide pins and screw in the two cylinder head mounting bolts in their place.
7. Gradually tighten the cylinder head bolts in several stages in the sequence shown in Figure Cylinder head bolt tightening sequence for 1.8-I, AGN/AGU four-cylinder engine or Figure Cylinder head bolt tightening sequence for 1.6-I, AEH/AKL four-cylinder engine.
Warning: Do not tighten the cylinder head mounting bolts on a warm engine. When installing a new cylinder head with camshaft, after installing the cylinder head, lubricate the mating surfaces of the hydraulic tappets and camshaft cams with a thin layer of grease.
8. Turn the crankshaft and camshaft to a position so that they correspond to the installation of the piston of the first cylinder at TDC in the compression stroke.
9. Before installing the inner cylinder head cover gasket, lubricate the surfaces mating with the gasket with a thin layer of D2 sealant (the places where the sealant should be applied are indicated by arrows). Install the cylinder head cover gasket.
10. Install the cylinder head cover and gradually and sequentially tighten the cover mounting nuts in a crosswise pattern to a torque of 10 Nm.
11. Install the timing belt on the camshaft pulley and adjust its tension.
12. Screw on the exhaust pipe with the catalytic converter.
Engine 1.8-I-Turbo
13. Bolt the heat shield and turbocharger air pipe to the rear of the cylinder head.
14. Install the intake manifold with a new gasket on the cylinder head and secure it with bolts, tightening them to a torque of 10 Nm.
15. Bolt the lower part of the intake manifold to the holders, tightening the mounting bolts to a torque of 25 Nm.
16. Connect the fuel supply and return lines to the fuel rail.
17. In accordance with the previously made markings, connect all electrical connectors to the cylinder head.
Engine 1.8-I
18. Install the V-belt tensioner mechanism and secure it with the bolt, tightening it to a torque of 25 Nm.
19. Install the V-belt.
20. Install the timing belt covers.
21. Screw in the spark plugs.
22. Check that all hoses, lines and electrical connectors are connected as previously marked.
23. Check the engine oil level and top it up if necessary. If the old cylinder head gasket was defective, replace the engine oil.
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24. Fill the cooling system with fresh coolant.
25. Install the air filter.
26. Connect the ground wire to the battery.
27. Start the engine and warm it up to operating temperature. Turn off the engine and check the engine oil and coolant levels, as well as the tightness of all connections.
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