Cylinder head, assembly overview: Notes

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Checking compression. Refer to Compression pressures, checking

NOTE:

When installing an exchange cylinder head complete with installed camshafts, oil the contact surfaces between lifters and cam lobes before installing valve cover.
Do NOT remove the plastic packing pieces which protect the open valves until immediately before installing the cylinder head.
If the cylinder head is replaced, replace the entire engine coolant mixture.

Fig 1: Exploded View Of Cylinder Head Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Toothed belt guard - upper part

2 - Toothed belt

Mark direction of rotation before removing
Check for wear
Do not kink
Removing and installing, adjusting. Refer to Toothed belt, removing, installing and tensioning

3 - 20 Nm

4 - 20 Nm

5 - 45 Nm

6 - Camshaft sprocket

Use puller T40001 for removal

7 - Tensioning roller

Semi-automatic toothed belt tensioning roller, checking. Refer to Semi-automatic toothed belt tensioning roller, checking

8 - Idler roller

9 - Rear toothed belt cover

10 - 10 Nm

11 - Lifting eye

12 - Cylinder head bolt

Always replace
Observe sequence for loosening and tightening. Refer to Cylinder head, removing and installing

13 - Oil deflector

14 - Valve cover

With vulcanized gasket
Replace complete if damaged or leaking

15 - Sealing sleeve

Replace if damaged

16 - Cap

Replace seal if damaged

17 - Ventilation line

18 - Clamp

19 - Pressure regulator valve

For crankcase ventilation

20 - Gasket

Replace if damaged

21 - 5 Nm

Engine code ALH

22 - Fuel injector lines

Tighten to 25 Nm
Remove and install using injector line wrench 3035
Always remove complete set of lines
Do not bend, kink or alter shape

23 - Vacuum pump

For brake booster

24 - Gasket

Always replace

25 - Fuel injector

Removing and installing. Refer to 23 DIESEL FUEL INJECTION for M.Y. 99-01, or 23 DIESEL FUEL INJECTION from M.Y. 2002 and on

26 - Glow plug

15 Nm
Checking. Refer to 28 IGNITION/GLOW PLUG SYSTEM for M.Y. 99-01, or 28 IGNITION/GLOW PLUG SYSTEM for M.Y. 2002 and on.

27 - Cylinder head gasket

Always replace
Observe identification Cylinder head gasket identification under Cylinder Head Gasket Identification
After replacing replace entire amount of coolant