Installing the cylinder head (VW Passat B2)

Clean the removed parts and determine their technical condition by visual inspection. Clean the surfaces of the connectors using appropriate detergents. Do not use abrasive materials or objects that can leave scratches for cleaning. Replace all gaskets with new ones during assembly.

Install the cylinder head gasket with the surface with the inscriptions facing the plane of the cylinder head.

Install dowel pins 2083 into the holes for mounting bolts 9 and 10 (see photo) of the cylinder head.

Install new cylinder head bolts with new washers.

Tighten the cylinder head mounting bolts in three stages, observing the order (see photo) of tightening the bolts and tightening torques:

• 1st reception: 4.0 kgf·m;
• 2nd reception: 6.0 kgf·m;
• step 3: Turn 180°.

Install the camshaft drive belt and adjust its tension.

Check valve clearances and adjust them if necessary.

Install the exhaust manifold and attach the exhaust pipe flange using a new gasket.

Install the intake manifold.

Depending on the configuration, install the power steering pump, put on the drive belt and adjust its tension.

Connect the outlet hose to the radiator, connect the interior heating system hoses to the cylinder head, and connect the inlet hose to the radiator.

Install the throttle cable in place.

Screw the spark plugs into the cylinder head sockets.

Install the crankcase ventilation hose.

On the WN model engine

Connect the connectors of the electrical equipment units installed on the cylinder head and the connector of the intake manifold heater



Connect the vacuum hoses to the carburetor.

Connect the fuel lines.

Install the air filter.

On JS model engine

Install the injectors, having previously moistened the injector cuffs with gasoline, and tighten the injector mounting flange.

Put the disconnected injection system pipes back in place, replacing the gaskets on the fittings.

Install the air duct connecting the air flow meter to the throttle body.

On engines of WN and JS models

Further installation of the cylinder head is carried out in the reverse order of removal. After installation of the cylinder head, do the following:

(View the original on the website: www.VWmanual.ru)

• fill the cooling system with liquid;
• check the oil level in the engine crankcase;
• connect the wire to the battery;
• adjust the ignition timing and engine idle speed.

Check the valve clearances on a warm engine if the cylinder head has been disassembled.