Contents: Removal ↓ Installation ↓
Removal
1. Remove the brake booster vacuum hose from the vacuum pump on the side of the cylinder head.
2. Remove the coolant hose from the connecting pipe on the cylinder head above the thermostat housing.
3. Remove the thin coolant hose near cylinder 1 (from the toothed belt side) above the intake manifold.
4. Clean the connections of the pump and injector feed pipes with a cold cleaning agent, unscrew them. Close the holes to prevent contamination with appropriate caps.
Attention! Do not change the bend of the supply pipes.
5. Remove the fuel return hose from the 5th cylinder injector.
6. Remove the glow plugs and injectors (see subsection 2.17.7.2 and subsection 2.17.7.5).
7. Remove both timing belts.
Installation
1. Fine-tuning of the cylinder head of a diesel engine is not permitted.
2. When replacing a gasket, pay attention to the marking and install a new gasket of the same marking. The cylinder head gasket marking with holes and notches (arrow) is also visible when the cylinder head is installed. Depending on the piston protrusion, cylinder head gaskets of different thicknesses are installed.
3. Always replace the cylinder head gasket. The new gasket must have the same designation as the old one. Only after installing new pistons or engine parts can the new piston protrusion be measured and the new gasket thickness determined.
Caution! Always replace cylinder head bolts.
4. The cylinder head bolts of a diesel engine are tightened in the same way as those of a petrol engine. However, the cylinder head bolts of a diesel engine are additionally tightened when the engine is warm.
5. Install the glow plugs (see subsection 2.17.7.2).
6. Install the injectors (see subsection 2.17.7.5).
7. Clean the supply pipe connections with a cold cleaning agent. Tighten the union nuts to a torque of 25 Nm.
8. Place the fuel return hose onto the 5th cylinder injector.
9. Install both timing belts (see subsection 2.5.2.1).
10. Place the brake booster vacuum hose onto the vacuum pump on the side of the cylinder head and secure with a clamp.
11. Place a thin coolant hose near cylinder 1 above the intake manifold and secure with a clamp.
12. Place the coolant hose onto the connecting pipe on the cylinder head above the thermostat housing and secure with a clamp.
13. Check the start of the injection pump feed (see subsection 2.17.7.6).
(The information is presented on the website: VWManual)
Caution! Tighten the cylinder head bolts on a warm engine.
14. Warm up the engine until the fan comes on.
15. Remove the cylinder head cover.
16. Tighten all cylinder head bolts in the specified order (see Fig. Cylinder Head Bolt Tightening Sequence) with a rigid wrench without preliminary loosening and in one go by 1/4 turn (90°).
Attention! Further tightening of the cylinder head bolts after 1000 km of mileage is not allowed.
17. Install the cylinder head cover.
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