The cylinder head, made of light alloy, incorporates, in addition to two valves per cylinder, also unit injectors. Each unit injector combines a plunger pair of the fuel pump and a fuel injection nozzle. A common camshaft drives both the valves and the plunger pair of the unit injector, resulting in fuel being injected directly into the engine cylinder.
1 - Upper timing belt casing
2 - toothed belt
If the timing belt is to be reinstalled, the direction of rotation must be marked before removal. Removal and installation are carried out in the same way as for the 1.9-I-PD-TDI engine with a power of 100/130 hp, see here.
3 — bolt, 10 Nm
4 - bolt, 25 Nm
5 — bolt, 100 Nm
6-camshaft gear wheel
7 — hub
With a ring for the sensor. To release and tighten use the VW-T10051 holder, and to remove use the VW-T10052 puller.
8 - rear toothed belt protective screen
9 — cylinder head mounting bolt
Always replace the bolt with a new one. Before installation, install washers on the cylinder head.
Release sequence: 8 to 1.
Tightening sequence: from 1 to 8.
Tightening instructions:
Step 1: using a torque wrench with a torque of 40 Nm.
Method 2: using a torque wrench with a torque of 60 Nm.
Step 3: Tighten in the tightening direction by 90 (¼ turn).
Step 4: Tighten in the tightening direction by 90 (¼ turn).
10 - Hall sensor
To determine the position of the camshaft. To remove, detach the sealing insert "11" from the rear protective screen of the toothed belt.
11 — sealing insert**
12 — finger, 10 Nm
For engine cover.
13 — cylinder head cover
With a branch pipe for pouring engine oil. If the cylinder head cover is damaged, the branch pipe must also be replaced.
14 — hose to turbocharger
15 — bolt, 10 Nm
First tighten all the bolts by hand. Then tighten first the two top bolts, and then the remaining bolts in a crisscross pattern from the inside to the outside.
16 — pressure regulating valve
For the engine crankcase ventilation system.
17 — branch pipe for filling engine oil
18 — lid
With sealing ring**
19 — sealing cuff**
20 — holder
With fuel lines.
21 — cylinder head cover gasket **
22 — bolt, 20 Nm
23 — eye
24 - pump injector
25 - central plug connector
For pump injector.
26 — hose from the brake booster
27 - twin pump
Fuel and vacuum.
28 — fuel supply hose
White or, accordingly, with white markings, from the fuel filter.
29 — fuel drain hose
Blue or, accordingly, with blue markings, to the fuel filter.
30 — seals*
31 — holder
32 - Hexagonal cone nut
33 — cylinder head
34 — cylinder head gasket*
35 - glow plug, 15 Nm
36 - tension roller
37 — bolt, 20 Nm + 45° (⅛ turn) in tightening direction
*) Always replace.
**) Replace if damaged.
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