Cylinder head, assembly overview

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Volkswagen > A4 Platform > 1999 - 2005 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH 15 - Engine - Cylinder head, Valvetrain Cylinder head, assembly overview Checking compression

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.

http://www.ebahn.com/VW/A/A4/Repair Manuals/GE01/VW-A4-GE01-15-001-01.... 2/23/2006

Cylinder head, assembly overview

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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

Toothed belt, removing, installing and tensioning

3 - 20 Nm 4 - 20 Nm 5 - 45 Nm

http://www.ebahn.com/VW/A/A4/Repair Manuals/GE01/VW-A4-GE01-15-001-01.... 2/23/2006

Cylinder head, assembly overview

Page 3 of 5

6 - Camshaft sprocket Use puller T40001 for removal 7 - Tensioning roller Semi-automatic toothed belt tensioning roller, checking tensioning roller, checking

Semi-automatic toothed belt

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 installing, Cylinder head, removing and installing

Cylinder head, removing and

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

http://www.ebahn.com/VW/A/A4/Repair Manuals/GE01/VW-A4-GE01-15-001-01.... 2/23/2006

Cylinder head, assembly overview

Page 4 of 5

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 1.9 Liter 4-Cyl. 2V TDI Fuel Injection Glow Plug, Engine Code(s): ALH - Repair Group 23 26 - Glow plug 15 Nm Checking 1.9 Liter 4-Cyl. 2V TDI Fuel Injection Glow Plug, Engine Code(s): ALH Repair Group 28 27 - Cylinder head gasket Always replace Observe identification After replacing replace entire amount of coolant

http://www.ebahn.com/VW/A/A4/Repair Manuals/GE01/VW-A4-GE01-15-001-01.... 2/23/2006

Cylinder head, assembly overview

Page 5 of 5

Checking cylinder head for distortion Max. permissible distortion: 0.1 mm Note: Reworking diesel cylinder heads is not permitted.

Cylinder head gasket identification Replacement part No. = - arrow 1 Holes = - arrow 2 Production control code = - arrow 3 - disregard Note: Different thicknesses of cylinder head gasket are installed depending on the piston projection dimension. When replacing the cylinder head gasket, install a new gasket with the same identification.

http://www.ebahn.com/VW/A/A4/Repair Manuals/GE01/VW-A4-GE01-15-001-01.... 2/23/2006