Overview - Cylinder Head

1. Cylinder Block
2. Cylinder Head Gasket
   • Replacing. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .
   • Cylinder head gasket identification. Refer to Fig 3.
3. Cylinder Head
   • Removing and Installing. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .
   • Only set the removed cylinder head down on a foam insert. Otherwise the glow plugs can be damaged.
   • Checking for distortion. Refer to Fig 2.
   • Must not be reworked
   • Make sure both alignment sleeves for centering the cylinder head on the cylinder block are actually there before installing.
   • Check the plug at the transmission side of the cylinder head for tight seating -item  : Plug.
   • After removing and installing change the coolant and engine oil
4. Fitted Pin
   • For the camshaft housing
5. Bolt with Washer
   • Replace after removing
   • Loosening sequence. Refer to Removing - .
   • Tightening specification and sequence. Refer to Fig 4.
6. Bolt
   • 20 Nm
7. Engine Lifting Eye
8. Spacer Ring
   • Replace if damaged
9. O-Ring
   • Replace if damaged or leaking
   • Coat with coolant
10. Engine Coolant Temperature Sensor -G62-
    • Removing and Installing. Refer to Engine Coolant Temperature Sensor -G62-, REMOVING AND INSTALLING .
11. Double Bolt
    • Tightening specification Item: Double Bolt .
12. Fitted Pin
    • For the camshaft housing
13. Connection
    • For the coolant hoses
14. Bolt
    • 10 Nm
15. Seal
    • Replace after removing
16. Fitted Pin
    • For intake manifold with charge air cooler
17. Alignment Sleeves

Cylinder Head, Checking for Distortion 

-- Check the cylinder head at several locations for distortion using a Straight Edge - 500mm: VAS 6075  and a feeler gauge.

• Maximum permissible distortion: 0.1 mm.
• It is not permitted to re-work the cylinder heads on TDI engines

Cylinder Head Gasket Identification 

1. Part Number
2. Ignore
3. Holes

• Depending on the piston projection, varying cylinder head gasket thicknesses can be installed. Refer to PISTON PROJECTION, MEASURING AT TDC . If replacing the cylinder head gasket, make sure the new cylinder head gasket has the same identification.

Cylinder Head - Tightening Specification and Sequence 

-- Replace the bolts.

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

Step	Bolts	Tightening Specification/Additional Turn
1.	-1 through 10-	30 Nm
2.	-1 through 10-	70 Nm
3.	-1 through 10-	90° additional turn
4.	-1 through 10-	90° additional turn
5.	-1 through 10-	90° additional turn