Cylinder head cover, removing and installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Spring-Type Clip Pliers VAS 5024A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Spring-type clip pliers VAS 5024A

Fig 2: Torque Wrench V.A.G. 1331 (5 To 50 Nm)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1331

Removing

NOTE:

To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With ignition switched off disconnect battery Ground (GND) strap.

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Remove engine cover.

Fig 3: Identifying Ignition Coils

Courtesy of VOLKSWAGEN UNITED STATES, INC.

On engine codes BJS remove the ignition coils with power output stages for cylinders 1 through 6 using the puller for ignition coil T10095 A, refer to Ignition coils with power output stage, removing and installing .
Remove intake manifold, refer to Intake manifold, removing and installing .
Remove cylinder head cover.

Installing

Installation is performed in reverse order of removal. Note the following:

NOTE:

Replace cylinder head cover and/or seal if damaged or leaking.
First, bolt the intake manifold to the cylinder head. Then, fasten bolts for shield and intake manifold support.
Ensure fuel hoses are seated securely.

Torque specifications

Bolted connections		Torque specifications
Cylinder head cover to cylinder head		10 Nm
Intake manifold to cylinder head		15 Nm
Intake manifold to support		20 Nm
Shield to exhaust manifold		23 Nm
Oil dip stick guide tube to intake manifold		5 Nm