Cylinder head, removing

Fig 1: Identifying Special Tools - Cylinder Head, Removing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Drip tray for workshop crane VAS 6208
Retainer 3036
Puller T40001
Ignition Coil Puller T40039

Hose clamp pliers V.A.G 1921
Polydrive bit and drive socket T10070

Special tools, testers and auxiliary items required

Fig 2: Identifying Special Tool T10020 Two Hole Pin Wrench

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Toothed Belt Tensioner T10020

Fig 3: Locking Tool T40098

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Locking Tool T40098

Removing

Engine installed.

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
Perform oil change if engine oil is contaminated →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
If using sealant, note current specifications

Note radio code (for vehicles equipped with coded anti-theft radio/radio navigation system), obtain if necessary.

Fig 4: Removing Engine Cover

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Remove engine cover - arrows -.

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Fig 5: Identifying Exhaust Pipe Fasteners

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For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 6: Identifying Quick-Release Fasteners And Noise Insulation

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Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Drain engine coolant → Cooling system, draining and filling
Remove toothed belt → Toothed belt, removing and installing .

Fig 7: Loosening Bolt For Camshaft Sprocket Using Retainer 3036

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Loosen bolt for camshaft sprocket using Retainer 3036.

Fig 8: Pulling Off Camshaft Gear Using Puller T40001, Claw T40001/6 And Claw T40001/7

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Remove camshaft sprocket using two-arm puller T40001 and claw T40001/6 and claw T40001/7.

Fig 9: Removing Rear Toothed Belt Housing From Cylinder Head

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Remove rear toothed belt housing - arrows - from cylinder head.

Fig 10: Identifying Ground (GND) Cable, Vacuum Line To Brake Booster At Bulkhead & EVAP Hose

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Unfasten Ground (GND) cable - 1 -.
Disconnect vacuum line to brake booster at bulkhead - 2 -.
Disconnect EVAP hose - 3 -.

Fig 11: Removing Coolant Hoses And Unfastening Coolant Expansion Tank

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Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -.
Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

Fig 12: Separating Electrical Connector From Charge Air Pressure Sensor G31 & Removing Left Charge Air Hose

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Separate electrical connector from Charge Air Pressure Sensor G31 - 1 -.
Remove left charge air hose - 2 -.

Fig 13: Removing Air Duct Hoses

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Remove air duct hose - 1 - to turbocharger at bottom right.
Remove air duct hose - 2 - to charge air cooler at lock carrier.

Fig 14: Disconnecting Connector & Separating Intake Hose

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Disconnect connector - 1 and 2 - and free up cable.

Fig 15: Removing Oil Supply Line For Turbocharger At Cylinder Block & Bolting Of Support For Turbocharger

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Remove oil supply line for turbocharger at cylinder block - 1 -.
Remove bolt - 2 - of support for turbocharger.

Fig 16: Removing Oil Supply Line For Turbocharger

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Remove oil supply line for turbocharger - arrows -.

Fig 17: Disconnecting Oil Return Line From Turbocharger

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Disconnect oil return line - arrows - from turbocharger.

Fig 18: Locating Bolt Of Support For Turbocharger

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Loosen bolt - 1 - of support for turbocharger by 2 turns.
Remove intake manifold → - 24 - MULTIPORT FUEL INJECTION (MFI)
Remove catalytic converter → Catalytic converter, removing and installing
Remove cylinder head cover → Cylinder head cover, removing and installing

Fig 19: Identifying Cylinder Head Bolts Loosing Sequence

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Loosen cylinder head bolts, paying attention to sequence of cylinder head bolts.

NOTE:

Verify that all hose and line connections between engine, transmission and body have been disconnected.

Remove cylinder head.

Cylinder head, installing

NOTE:

Replace cylinder head bolts.
Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings.
Secure all hose connections using hose clamps of series-production status
Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
Carefully remove all grinding and sanding residue.
Only unpack new cylinder head gasket immediately prior to installation.
Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.
There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Hot bolt paste

CAUTION: Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

NOTE:

Turning over the engine is performed at the center bolt of the crankshaft.

Fig 20: Bringing Marking On Camshaft Gear To Alignment With Marking On Toothed Belt Guard

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Bring marking on camshaft gear to alignment with marking on toothed belt guard. Recesses - arrows - now point to each other vertically.
In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
Set cylinder head gasket in place.

Fig 21: Identifying Cylinder Block Centering Pins

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Pay attention to centering pins in cylinder block - arrows -.

Observe cylinder head seal location, identification: Replacement part number must be visible from intake side

Set cylinder head in place.
Insert cylinder head bolts and tighten by hand.

Fig 22: Identifying Cylinder Head Bolts Tightening Sequence

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Tighten cylinder head in sequence indicated, in two stages as follows:
Tighten with torque wrench:

1. Step: 40 Nm

Tighten using a solid wrench:

2. Step: 180 ° (¹ /₂ turn) further (2 x 90 ° further is permissible)

NOTE:

There is no requirement to retighten the cylinder head bolts after repairs.

Install cylinder head cover → Cylinder head, removing .
Install toothed belt → Toothed belt, removing and installing .
Install ribbed belt → Ribbed belt, removing and installing .
Electrical connections and routing → Electrical Wiring Diagrams, Troubleshooting and Component Locations

Install intake manifold → - 24 - MULTIPORT FUEL INJECTION (MFI)
Connect battery → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Install fuel system → - 24 - MULTIPORT FUEL INJECTION (MFI)
Check oil level →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Fill with coolant → Cooling system, draining and filling .

NOTE:

Only reuse drained coolant if cylinder head or engine block was not replaced.
Dirty coolant must not be re-used.

Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 23: Identifying Lock Carrier With Attachments

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Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

CAUTION: Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.

Torque specifications

Component		Nm
Bolts/nuts	M6	10
	M8	20
Exceptions:
Front exhaust pipe to turbocharger		30 ¹⁾³⁾
Cylinder head cover to cylinder head		10
Toothed belt guard to cylinder block		10 ²⁾
Battery clamp to battery terminal		6
Torque support stop		28
¹⁾ Replace bolt or nut ²⁾ Insert using locking compound ³⁾ Coat studs of exhaust manifold and threads of oxygen sensor with hot bolt paste; Hot bolt paste