Removal and installation the cylinder head of a diesel engine (VW Passat B5)

Cylinder head of diesel engine 1.9-I-TDI

1 - cylinder head cover;
2 - Oil filler cap. If the cap is not tight, replace the gasket;
3 - sealing gasket. If the gasket is damaged, it must be replaced;
4 - disc washer;
5 - nut, 10 Nm;
6 - cap;
7 - to the intake manifold;
8 - clamp;
9 - pressure regulating valve;
10 - Sealing bushing. If there is any damage, a new sealing bushing must be used.
11 - Cylinder head cover gasket;
12 - crankcase ventilation hose;
13 - Cylinder head mounting bolt. New bolts must be used during installation. Bolt tightening torques are the same as for a four-cylinder petrol engine;
14 - clamp;
15 - O-ring. A new O-ring must be used during installation;
16 - conical sealing ring;
17 - High-pressure fuel supply lines to the fuel injectors. The lines must be replaced as a set. Do not bend the lines. Tighten the line union nuts to 25 Nm;
18 - cylinder head;
19 - cylinder head gasket;
20 - bolt, 20 Nm;
21 - Engine lifting eye

Marking of cylinder head cover gasket with holes and number

All operations for removing and installing the cylinder head of a diesel engine are the same as those for removing and installing the cylinder head of a gasoline four-cylinder engine. This subsection only provides the differences for diesel engines.

Execution order

1. Remove the timing belt.

2. Disconnect the voltage supply line from the glow plugs.

[The information is available on the website: VWmanual.ru]

3. Clean the connection points of the pipes to the fuel injectors and the high-pressure fuel pump. Unscrew the union nuts and remove the fuel pipes. Close the holes with suitable plugs.

4. Remove the glow plugs and fuel injectors from the cylinder head.

5. To unscrew the cylinder head mounting bolts, use the appropriate socket wrench (for example, HAZET 990 Sig-12).

6. Tighten the cylinder head mounting bolts in the same sequence and with the same torque as on four-cylinder petrol engines.

Warning: The cylinder head of a diesel engine must not be machined.

7. If new pistons are installed on the engine, the piston protrusion from the cylinder block must be measured and the thickness of the new cylinder head gasket must be selected based on the piston protrusion.