Cylinder Head Overview

Fig 1: Cylinder Head Overview

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1. Cylinder Head Gasket
   • Replacing. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .
   • Identification, refer to Fig 3.
   • Installed position: the part number faces the cylinder head.
   • Change the coolant and engine oil after replacing.
2. Bolt
   • Tightening specification. Refer to Special Tools .
3. Bolt
   • Tightening specification. Refer to Special Tools .
4. High Pressure Pump Toothed Belt Drive Sprocket
   • Removing and Installing. Refer to HIGH PRESSURE PUMP TOOTHED BELT, REMOVING AND INSTALLING .
5. Rear Toothed Belt Cover
6. Camshaft Seal
   • Replacing. Refer to CAMSHAFT SEAL, REMOVING AND INSTALLING .
7. Seals
   • Replace
8. Banjo Bolt
   • Tightening specification, refer to -Item 2- COOLANT PIPES OVERVIEW .
9. Fuel Rail
   • Follow the guidelines for clean working conditions. Refer to FUEL SUPPLY, INJECTION SYSTEM AND CHARGING SYSTEM CLEAN WORKING CONDITIONS .
   • Removing and Installing. Refer to Diesel Fuel Injection .
   • Do not change the angles of the high pressure lines.
   • High Pressure Lines, Removing and Installing. Refer to Diesel Fuel Injection
10. Bolt
    • Tightening specification. Refer to Special Tools .
11. Coolant Line
12. Bolt
    • Loosening sequence, refer to CYLINDER HEAD, REMOVING AND INSTALLING .
    • Replace
    • Tightening specification and sequence, refer to Fig 4.
13. Engine Lifting Eye
14. M8 Bolt
    • 23 Nm
15. M6 Bolt
    • 9 Nm
16. Cylinder Head
    • Removing and Installing. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .
    • 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, refer to Fig 2.
    • It is not permitted to re-work the cylinder heads on TDI engines.
    • Change the coolant and engine oil after replacing.

Fig 2: Checking Cylinder Head For Distortion

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

• Maximum permissible warpage: 0.1 mm.

Fig 3: Cylinder Head Gasket Identification

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1. Holes
2. Part Number

Fig 4: Cylinder Head, Tightening Sequence

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-- Tighten the bolts in five steps in the sequence shown.