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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf IV (1997 release)

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Volkswagen Golf 4
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Removal and installation of the bottom mudguard of a motor compartment
Engine 1,6- / 1,8-I
The engine 1,4-I
Engine-I 2,3-VR5
Timing
Removal and installation of the cylinder head
Compression check in engine cylinders
Removing and installing V-ribbed belt
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Removing and installing oil pan
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Removal and installation of the cylinder head



Cylinder head assembly of the engine 2,3-I-VR5

.1 - The upper part of the intake manifold. The upper part of first inlet attached to the bottom portion of the inlet manifold, and then into the manifold assembly to the cylinder head;
2 - the throttle body;
3 - a bolt, 10 Nm;
4 - a cover;
5 - the cylinder head cover. When replacing the cover, on the perimeter of the cover in the segment recess, apply sealant WV-D454300A3;
6 - an arm;
7 - a bolt, 25 Nm;
8 - bolt cylinder head. When installing it is necessary to use new bolts and tightening bolts make in a certain sequence in several stages;
9 - cylinder head. When flatness of 0.1 mm is necessary to make regrinding of the cylinder head. Minimum permissible height of the cylinder head 139.5 mm;
10 - the O-ring. When installing, use a new O-ring lubricated with clean engine oil;

11 - a cover of the drive chain. Removing and installing timing chain cover may only be installed on the cylinder head. When replacing the cover of the drive chain is necessary to fill the holes in the end cap sealing fluid VW-AMV18800102;
12 - chain tensioner, 40 Nm. The engine can be turned only with the established chain tensioner;
13 - a sealing ring;
14 - the water pump;
15 - the block of the ignition system;
16 - the cover of the thermostat;
17 - a sealing ring. If tightness is necessary to use a new sealing ring;
18 - cylinder head gasket. When installing, use a new cylinder head gasket;
19 - lower part of the intake manifold;
20 - to seal the upper portion of the inlet manifold. If the damage is necessary to use a new seal;
21 - bolt 5 Nm;
22 - combined valve;
23 - to seal the bottom portion of the inlet manifold. If the damage is necessary to use a new seal;
24 - V-belt tensioning mechanism;
25 - bolt 5 Nm;
26 - an arm;
27 - the vacuum actuator

Sequence of a tightening of bolts of the cylinder head on the engine VR5


A warning

Operations on removal and installation of the cylinder head of the engine VR5 similar to operations on removal and installation of the cylinder head on the four-cylinder gasoline engine. This section describes only the differences for the removal and installation of the cylinder head engines VR5.


PERFORMANCE ORDER
1. Remove the attachments from the cylinder head and cylinder head cover.
2. Unscrewing the bolts fastening the cylinder head make in sequence, return to their tightening (see. Fig. Sequence of a tightening of bolts of the cylinder head on the engine VR5).
3. Clean holes (indicated by arrows) with a diameter of 3 mm from the sealant in the end caps transmission chains.
4. Fill in the holes in the end cap drive chain liquid sealant VW-AMV18800102.

A warning

After installation of the cylinder head for opening the sealant in the end caps of the drive chain are closed halfway.


5. Before installing the cylinder head gasket, check that the holes 15 and 16 (see. Fig. Sequence of a tightening of bolts of the cylinder head on the engine VR5) cylinder mounted guides.
6. Carefully set the head on the block of cylinders. Insert and hand-tighten the bolts and washers securing the cylinder head.
7. In a certain sequence (see. Fig. Sequence of a tightening of bolts of the cylinder head on the engine VR5) tighten all the bolts tightening torque of 30 Nm, then tighten all the bolts tightening torque of 50 Nm and finally in two steps tighten all bolts, each time for 90 ?�.




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Compression check in engine cylinders

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