Cylinder Head

LEGEND
1 Expanding Clip
2 Toothed Timing Belt Guard, Upper Section
3 Toothed Timing Belt
4 Bolt
5 Camshaft Sprocket
6 Bolt
7 Toothed Timing Belt Guard, Rear
8 Cylinder Head Cover
9 Cap
10 Upper Sealing Washer
11 Cup Washer
12 Cap
13 To Intake Hose
14 Retaining Clip
15 Positive Crankcase Ventilation (PCV) Valve
16 Gasket
17 Cylinder Head Cover Gasket
18 Crankcase Breather
19 Cylinder Head Bolt
20 Mounting Clip
21 O-Ring
22 Lower Sealing Cone
23 Injector Lines
24 Cylinder Head
25 Fuel Injector
26 Glow Plug
27 Lifting Eye
28 Cylinder Head Gasket
29 Bolt
30 Not Used
31 Not Used
32 Not Used
33 Not Used
34 Nut

NOTE:
- During removal and installation procedures, refer to the component location illustration above and component notes below.
- When installing an exchange cyl. head (complete with camshaft), the contacting surfaces between the hydraulic lifter and the cam face must be oiled after installing.
- The plastic protectors attached to the open valves must only be removed at the moment the cylinder head is to be installed.
- If the cylinder head is replaced, engine coolant must also be completely replaced.

CAUTION:
- Use care when turning crankshaft or camshaft while toothed timing belt is loose or disconnected.
- Piston valve contact is possible and may cause internal engine damage.

COMPONENT NOTES
Toothed Timing Belt (3)
- Mark running direction before removing.
- Check for wear.
- Do not kink.
- Removing and installing, refer to Timing Components.

Bolt (4)
- Tighten to: 45 Nm (33 ft. lbs.).


Camshaft Sprocket (5)
- Drive off camshaft taper using hammer and drift through toothed timing belt guard openings.

Bolt (6)
- Tighten to: 10 Nm (7 ft. lbs.).


Cap (9)
- Replace seal if damaged.

Upper Sealing Washer (10)
- Replace if damaged.

PCV Valve (15)
- For crankcase breather.

Gasket (16)
- Replace if damaged.

Cylinder Head (Valve) Cover Gasket (17)
- Replace if damaged.
- Insert projections into holes on cylinder head.

Cylinder Head Bolt (19)
- Always replace.
- Loosen bolts in reverse of tightening sequence shown below.
- Tighten in four steps as shown below.

O-ring (21)
- Always replace.

Injector Lines (23)
- Tighten to: 25 Nm (18 ft. lbs.).
- Remove using injector nut wrench tool No. 3035, or equivalent.
- Always remove fuel lines as an assembly.
- Do not bend or alter shape.

Cylinder Head (24)
- Check for distortion, refer to Testing and Inspection.
- Maximum permissible distortion: 0.1 mm (0.0039 inch).
- Installation, refer to procedure below.
- If cylinder head is to be replaced, always completely replace coolant.
- Reworking a diesel cylinder heads gasket surface is not permissible.

Fuel Injectors (25)
- To remove and install, refer to Powertrain Management.
- Always replace injector seals.

Glow Plug (26)
- Tighten to: 25 Nm (18 ft. lbs.).
- For testing, refer to Powertrain Management.

Cylinder Head Gasket (28)
- Always replace.
- Note head gasket markings during removal, replace with same thickness gasket.

Bolt (29)
- Tighten to: 20 Nm (15 ft. lbs.).

Nut (34)
- Tighten to: 45 Nm (33 ft. lbs.).


INSTALLATION


NOTE:
- Different thicknesses of cylinder head gasket are installed depending on the piston projection.
- When replacing the head gasket, always install a new gasket with the same identification.
- Always replace cylinder head bolts.
- Carefully remove seal/gasket remains from cylinder head and cylinder block Ensure that no longitudinal grooves or scratches are created.
- When using abrasive paper do not use a grade coarser than 100
- Carefully remove any abrasive debris.
- Remove new cylinder head gasket from packaging, just before installing.
- Handle gasket extremely carefully. Damaging the silicone layer or the indented area of metal gaskets can cause leakage.
- When using new style metal gaskets, re-torquing cylinder head after repairs is not necessary.

Special Tools, Testers And Auxiliary Items
^ VAG 1332 Torque wrench 40 to 200 Nm (30 to 150 ft. lbs.)
^ Guide pins 3070

Installation Notes
1. Turn crankshaft to Top Dead Center (TDC) marking before fitting cylinder head
2. Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below TDC.





3. Install cylinder head gasket
4. To centralize gasket, screw guide pins from head alignment tool No. 3070, or equivalent, into the outer threaded holes on the intake side.
5. Install cylinder head, thread in the 8 remaining cylinder head bolts and tighten by hand.
6. Remove guide pins using removal tool from head alignment tool and install remaining cylinder head bolts.





7. On models with new style metal gaskets, tighten cylinder head in four stage in sequence as shown:
- Tighten initially using a torque wrench:
- Stage I: 40 Nm (30 ft. lbs.).
- Stage II: 60 Nm (44 ft. lbs.).
- Turn further using a hand wrench:
- Stage III: 1/4 turn (90°).
- Stage IV: 1/4 turn (90°).

NOTE: It is NOT necessary to re-torque cylinder head bolts after the first 1,000 km (600 ml).

8. On models with old style plastic head gaskets, tighten cylinder head in four stage in sequence as shown:
- Tighten initially using a torque wrench:
- Stage I: 40 Nm (30 ft. lbs.).
- Stage II: 60 Nm (44 ft. lbs.).
- Turn further using a hand wrench:
- Stage III: 1/4 turn (90°).
- Stage IV: 1/4 turn (90°).

NOTE: In the following step DO NOT loosen head bolts.

- After final assembly run engine until completely warm (oil temperature at least 50°C (122°F)), then tighten head bolts in sequence an additional 1/4 turn (90°).

NOTE: It is NOT necessary to re-torque cylinder head bolts after the first 1,000 km (600 miles).


9. On all models, after tightening the cylinder head, rotate camshaft so cam for No. 1 cyl. points evenly upward.
10. Rotate crankshaft, in running direction of engine to TDC before fitting toothed timing belt