Cylinder head - assembly and disassembly — VW

VW
Polo
2003
Polo
2007
Polo
2012
Polo Sedan
2003
Polo Sedan
2007
Polo Sedan
2012
Power unit
4 - Cyl. injection engine
Edition
06.2014
Cylinder head - assembly and disassembly
Check compression (see the separate procedure).
Note
When a replacement cylinder head is assembled, it is necessary to lubricate all contact surfaces between support elements and valve seats, before assembling the cylinder head.
The plastic shims provided for protecting the open valves should not be removed until immediately before fitting the cylinder head.
When replacing the cylinder head, all coolant must also be replaced.
With the cylinder head removed, use the
Plate
VW 5541/3 to fasten the cylinder head and valve support.
WARNING
Always replace self-locking nuts and screws subject to angular torque
20 Nm + 90°
Replace after each removal.
To loosen and tighten, immobilize the camshaft gear with the
Special wrench
3036.
Camshaft gear
Observe fastening during assembly.
Check the installation position of toothed belt (see the separate procedure).
10 Nm
Apply
Liquid sealant
D 000 600 A2.
Front cover of the mechanical distribution
Cylinder head cover
Sealing surfaces cannot be ground.
Cover and head form a pair; therefore, the pair engraving is on the exhaust manifold side, close to
Hall Sensor
G40.
With integrated camshaft bearings.
Remove all sealant residues.
Apply
Sealant compound for engines
AMV 188 001 02 or
Sealant compound for engines
D 154 103 A1 before positioning.
For assembly, place in vertical position from top with guides in cylinder head holes.
Removal and installation (see the separate procedure).
Engine cylinder head screw
Replace after each removal.
Observe assembly and sequence instructions when loosening and tightening (see the separate procedure).
Oil deflector
Check assembly position.
It must be pressed to remove and install.
Oil reservoir lid
Replace sealing when damaged.
Finishing
Replace when damaged.
6 Nm + 90°
Replace after each removal.
Observe installation and sequence instructions when loosening and tightening (see the separate procedure).
10 Nm
Support
For ignition cables.
Guide pin
Roller rockers
Check the roller bearing.
Lubricate the contact surface with oil.
For installation, fit the safety clip to the support element.
Supplier
“INA” with
“030” engraving on the side near the spherical region.
Supplier
“GTT” with
“S3011” engraving on the upper side near the spherical region.
Do not mix, as in a single head only parts from the same supplier may be installed.
Support element
Do not change the working position.
With valve clearance hydraulic offsetting.
Lubricate the contact surface with oil.
Supplier
“INA” with
“I” engraving on the bottom of the support element.
Supplier
“GTT” with
“GT” engraving on the bottom of the support element.
Do not mix, as in a single head only parts from the same supplier may be installed.
Cylinder head sealing gasket
Metal gasket.
Replace.
After replacing, replace coolant.
Engine cylinder head
The sealing surface on the camshaft side must not be ground.
The head and the cover form a pair; therefore, the engraving for the pair is on the exhaust tube side, close to
Hall Sensor
G40.
When replacing, check printed code on the cover and cylinder head, they must be the same.
Check warping
Fig.
After replacing, replace coolant.
Disassembly and assembly (see the separate procedure).
Cooling system pipes
Cooling system hose connection diagram (see the separate procedure).
20 Nm
Camshaft
Repair (see the separate procedure).
Removal and installation (see the separate procedure).
Camshaft seal
Seal with spring
Quickly lubricate with oil the sealing ring lip.
Seal without spring
The sealing ring lip does not require lubrication.
Replace (see the separate procedure).
Check for warping of the cylinder head
Max. permissible bending: 0.05 mm.