Cylinder Head Overview

Cylinder Head Overview

• The illustration shows the cylinder bank 2 cylinder head (left).






1 Cylinder Head Gasket

• Removing and installing, refer to => [ Cylinder Head ] Cylinder Head

• Installation position: Parts number to cylinder head

• After replacing, change coolant and engine oil

2 Bolt

3 Bolt

4 High Pressure Pump Toothed Belt Drive Sprocket

5 Rear Toothed Belt Guard

6 Camshaft Seal

• Removing and installing, refer to => [ Camshaft Seal ] Service and Repair

7 Seals

• Replace

8 Banjo Bolt

• Tightening specifications - item 2 - => [ (Item 2) Banjo Bolt ] Coolant Pipes Overview

9 Fuel Rail

• Note rules of cleanliness, refer to => [ Clean Working Conditions ] Clean Working Conditions

• Do not change the angles of the high pressure lines

10 Bolt

11 Coolant Pipe

12 Bolt

• Replace

• Loosening sequence => [ Loosen the cylinder head bolts in the following sequence. ] Cylinder Head

13 Engine Lifting Eye

14 M8 Bolts

• 23 Nm

15 M6 Bolt

• 9 Nm

16 Cylinder Head

• Removing and installing, refer to => [ Cylinder Head ] Cylinder Head

• Do not lay the cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface

• Check for distortion

• It is not permitted to re-work the cylinder heads on TDI engines

• After replacing, change coolant and engine oil

Checking Cylinder Head for Distortion





- Check the cylinder head for distortion with the straight edge and feeler gauge in several places.

• Maximum permissible distortion: 0.1 mm

Cylinder Head Seal Identification





1. Holes

2. Part number:


• The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

Cylinder Head, Tightening Specifications and Sequence





• Replace bolts which have been tightened to an additional torque.

- Tighten the bolts in 5 steps according to the tightening sequence: