Removal and installation the cylinder head (VW Passat B2)

Removal

Disconnect the wire from the negative terminal of the battery.

Disconnect the supply hose from the radiator and drain the coolant.

Remove the air filter.

Disconnect the fuel supply hose from the fuel pump, and the fuel drain hose from the carburetor, and close the openings of the hoses and fittings with plugs.

Remove the fuel drain compensation valve.

Disconnect the vacuum hoses from the carburetor.

Disconnect the connectors of the electrical equipment units installed on the cylinder head, disconnect the block from the intake manifold heater.



Disconnect the engine crankcase ventilation hose from the cylinder head cover.

Disconnect the wires from the spark plugs, remove the cover and the rotor of the ignition distributor sensor.

Remove the spark plugs.

Disconnect the throttle cable and secure it to the left side of the engine compartment.

Disconnect the outlet hose from the radiator. Disconnect the interior heating system hoses.



Loosen the bolts securing the flange of the muffler inlet pipe to the exhaust manifold.

Remove the intake manifold.

Turn the engine crankshaft to the position corresponding to the TDC of the end of the compression stroke of the piston of the 1st cylinder, aligning the mark on the crankshaft pulley with the edge of the protrusion "O" of the indicator on the cylinder block.

Remove the front timing belt cover.

Loosen the timing belt tension and remove it from the camshaft pulley.

Remove the camshaft timing pulley.

Remove the rear timing belt cover.

Remove the cylinder head cover.

Loosen the cylinder head mounting bolts.

Remove the cylinder head.

Installation

Clean all removed parts and check their technical condition. Wash mating surfaces with a suitable solvent. Never clean mating surfaces with a scraper or abrasive materials. Replace sealing gaskets during assembly.

The original text can be found at [vwmanual]

Install the cylinder head gasket so that the side of the gasket with the markings faces the cylinder head.

Install the cylinder head in place and tighten bolts 8 and 10 (see photo) to center it.

Tighten the new cylinder head mounting bolts, installing new washers.

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

• 1st reception: 4 kgf.m;
• 2nd reception: 6 kgf.m;
• 3rd step: turn 180 degrees.

Install the camshaft drive belt and adjust its tension (see above).


Check the clearances in the valve drive mechanism and adjust them if necessary.

Install the exhaust manifold and secure the exhaust pipe flange to it with a new gasket.

Install the intake manifold.

Connect the outlet hose to the radiator. Connect the heater hoses. Connect the inlet hose to the radiator.

Connect the throttle cable.

Screw in the spark plugs.

Connect the engine crankcase ventilation hose to the cylinder head cover.

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

Connect the vacuum hoses to the carburetor.

Install a fuel drain compensation valve into the tank.

Connect the fuel supply hose to the fuel pump and the fuel drain hose to the carburetor.

Install the air filter.

Fill the engine cooling system with liquid.

Check the oil level in the engine crankcase.

Connect the wire to the negative terminal of the battery.

If the cylinder head was disassembled, adjust the ignition timing, engine idle speed, check the adjustment of the clearances in the valve drive mechanism on a hot engine.