Volkswagen Golf / Golf Plus. Manual - part 308

– Lift engine slightly using spindle -A- until spindle -B- is relieved.
– Unhook spindle -B- and push it to side.
Continuation for all vehicles
– Remove cylinder head cover. 

⇒ page 48

– Maintain sequence when loosening cylinder head bolts.
– Lift cylinder head slightly and remove from engine laterally

past toothed belt guard.

Note

The cylinder head must be guided carefully to prevent damage.

1.4.2

Installing

Note

♦

Always renew cylinder head bolts.

♦

In cases of repair carefully remove gasket remains from cyl‐

inder head and cylinder block. Ensure that no long scores or

scratches are created. When using abrasive paper do not use

a grade less than 100.

♦

Carefully remove remains of emery and abrasives.

♦

Do not remove new cylinder head gasket from packaging until

it is ready to be fitted.

♦

Handle gasket very carefully. Damage to the silicone coating

or the indented area will lead to leaks.

– Turn crankshaft to TDC marking before fitting cylinder head.
– Turn crankshaft opposite engine direction of rotation until all

pistons are approximately equally placed below TDC.

– Fit cylinder head gasket.

Note

Note identification on cylinder head gasket 

⇒ page 47

 .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

70

     Rep. Gr.15 - Cylinder head, valve gear

 

1 - Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2 - Turn further with rigid spanner:
Stage III = 

1

/4 turn (90°)

Stage IV = 

1

/4 turn (90°)

Note

After repair work it is not necessary to retighten the cylinder head

bolts.

Further installation is carried out in the reverse order. In the proc‐

ess, note the following:

– After tightening cylinder head, turn camshaft so that cams for

No. 1 cylinder equally point upwards. Before fitting toothed

belt, turn crankshaft in engine direction of rotation

⇒ page 50

 , removing, installing and tightening toothed belt.

– Install hub for camshaft toothed belt pulley 

⇒ page 147

 , Re‐

moving and installing camshaft.

– Install toothed belt 

⇒ page 50

 .

– Install poly V-belt 

⇒ page 13

 .

– Install oil supply line 

⇒ page 95

 .

– Install insulation tray ⇒  General body repairs, exterior; Rep.

Gr.  50 ; Body - front; Assembly overview.

– Install plenum chamber bulkhead ⇒  General body repairs,

exterior; Rep. Gr.  50 ; Body - front; Plenum chamber bulk‐

head .

– Fill cooling system with coolant 

⇒ page 102

 .

– Carry out road test and then read fault memory 

⇒ page 178

 .

1.5

Checking compression

Note

If ceramic glow plugs are fitted, before removing check idling

speed smooth running control using vehicle diagnostic, testing

and information system -VAS 5051B- . The compression test is

warranted only if one or more cylinders are conspicuous in this

idling speed check.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Cylinder head    

71

 

V.A.G 1331-

♦ Adapter -V.A.G 1381/12-
♦ Compression tester -

V.A.G 1763-

Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Pull off central connector for unit injectors.

Note

If ceramic glow plugs are fitted, always observe notes on remov‐

ing and installing ceramic glow plugs 

⇒ page 198

 .

– Remove all glow plugs or ceramic glow plugs using jointed

extension and socket -3220- .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

72

     Rep. Gr.15 - Cylinder head, valve gear

 

– Check compression using compression tester -V.A.G 1763- .

Note

Using compression tester ⇒ Operating instructions.

– Operate starter until tester shows no further pressure in‐

crease.

Compression pressures:
New: 25...31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar

Note

If ceramic glow plugs are fitted, always observe notes on remov‐

ing and installing ceramic glow plugs 

⇒ page 198

 .

– Remove glow plugs or ceramic glow plugs using jointed ex‐

tension and socket -3220- .

Specified torque: 15 Nm.
– Read fault memory of engine control unit. 

⇒ page 178

Note

Disconnecting the central connector for unit injectors causes

faults to be stored. Therefore, read fault memory and clear if nec‐

essary.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Cylinder head    

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