Volkswagen Golf / Golf Plus. Manual - part 308

 

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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    

73

 

 

 

 

 

 

 

 

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