Cylinder Head Overview

Cylinder Head Overview






1 Cylinder Head Gasket

• Always replace.

• Cylinder head gasket identification, refer to => [ Cylinder Head Gasket Identification ].

• After replacing, change the coolant and engine oil.

2 Bolt

• 10 Nm

• Install using locking compound, refer to the Parts Catalog.

3 Camshaft Position Sensor (G40)

• For the camshaft position.

• Removing and installing, refer to => [ Camshaft Position Sensor G40 ] Service and Repair.

4 Cylinder Head

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

• Only set the removed cylinder head down on a foam pad. Otherwise the glow plugs can be damaged.

• Checking for distortion, refer to => [ Checking the Cylinder Head for Distortion ].

• Must not be reworked.

• Make sure both alignment sleeves for centering the cylinder head on the cylinder block are actually there before installing.

• After replacing, change the coolant and engine oil.

5 Washer

6 Bolt

• Always replace.

• Loosening sequence, refer to => [ Cylinder Head Bolt Loosening Sequence ].

• Tightening sequence and specification, refer to => [ Cylinder Head Bolt Tightening Sequence and Specification ].

7 Oil Pressure Switch (F1)

• 20 Nm

• Switching pressure: 0.3 to 0.6 bar.

• Removing and installing, refer to => [ Oil Pressure Switch F1 ] Service and Repair.

• Checking, refer to => [ Oil Pressure Switch, Checking ] Testing and Inspection.

8 Seal

• Always replace.

9 Bolt

• 20 Nm

10 Engine Lifting Eye

11 Seal

• Always replace.

12 Bolt

• 20 Nm

13 Gasket

• Always replace.

14 Vacuum Pump

• Removing and installing, refer to => [ Vacuum Pump ] Service and Repair.

15 Bolt

• 10 Nm

16 Connecting Piece

• For the coolant hoses.

• With the engine coolant temperature sensor.

17 Bolt

• 9 Nm

18 Gasket

• Always replace.

19 Bolt

• 20 Nm

20 Engine Lifting Eye

Cylinder Head Bolt Loosening Sequence





- Loosen the cylinder head bolts in sequence - 1 through 10 -.

Checking the Cylinder Head for Distortion





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

• Maximum permissible distortion: 0.1 mm.

• It is not permitted to rework the cylinder heads on TDI engines

Cylinder Head Gasket Identification





• Part number - arrow 1 -

• Holes - arrow 2 -

• Control code - arrow 3 - (ignore this!)

• Depending on the piston projection, varying cylinder head gasket thicknesses can be installed. If replacing the cylinder head gasket, make sure the new cylinder head gasket has the same identification.

Cylinder Head Bolt Tightening Sequence and Specification





• Replace the cylinder head bolts.

- Tighten the bolts in 4 steps in the sequence shown: