Cylinder Head Overview
NOTE:
The illustration shows the cylinder bank 2 cylinder head (left).
- Cylinder Head Gasket
- Removing and installing, refer to CYLINDER HEAD
- Identification, refer to Fig 3
- Installation position: Parts number to cylinder head
- After replacing, change coolant and engine oil
- Bolt
- Tightening specifications, refer to Description and Operation
- Bolt
- Tightening specifications, refer to Description and Operation
- High Pressure Pump Toothed Belt Drive Sprocket
- Removing and installing, refer to Removal and Installation
- Rear Toothed Belt Guard
- Camshaft Seal
- Removing and installing, refer to CAMSHAFT SEAL
- Seals
- Replace
- Banjo Bolt
- Tightening specifications, refer to "Banjo Bolt" in numbered list under COOLANT PIPES OVERVIEW
- Fuel Rail
- Note rules of cleanliness, refer to CLEAN WORKING CONDITIONS
- Removing and installing, refer to Removal and Installation
- Do not change the angles of the high pressure lines
- High pressure lines, removing and installing, refer to Removal and Installation
- Bolt
- Tightening specifications, refer to Description and Operation
- Coolant Pipe
- Bolt
- Replace
- Loosening sequence LOOSEN THE CYLINDER HEAD BOLTS IN THE FOLLOWING SEQUENCE -1 THROUGH 8-
- Tightening specification and sequence, refer to Fig 4
- Engine Lifting Eye
- M8 Bolts
- 23 Nm
- M6 Bolt
- 9 Nm
- Cylinder Head
- Removing and installing, refer to 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, refer to Fig 2
- It is not permitted to re-work the cylinder heads on TDI engines
- After replacing, change coolant and engine oil
-- Check the cylinder head for distortion with the straight edge and feeler gauge in several places.
- Maximum permissible distortion: 0.1 mm
- Holes
- Part number:
NOTE:
The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.
NOTE:
Replace bolts which have been tightened to an additional torque.
-- Tighten the bolts in 5 steps according to the tightening sequence:
| Step | Bolts | Tightening Torque/Additional Angle of Rotation |
|---|---|---|
| 1. | -1 through 8- | Install all the way in by hand. |
| 2. | -1 through 8- | 35 Nm |
| 3. | -1 through 8- | 60 Nm |
| 4. | -1 through 8- | Tighten an additional 90°. |
| 5. | -1 through 8- | Tighten an additional 90°. |