Cylinder Head Overview

Fig 1: Identifying Assembly Overview: Cylinder Head

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Cylinder Head Gasket 
   • Always replace.
   • Note the installed position: The replacement part number must be visible from the intake side.
2. Bolt 
   • 25 Nm
3. Transport Strap 
4. Bolt 
   • Always replace.
   • Follow the sequence when loosening, refer to Fig 3.
   • Tightening sequence and specification, refer to Fig 4.
5. Cylinder Head 
   • Check for distortion, refer to Fig 5.
   • Removing and installing, refer to CYLINDER HEAD .
   • Checking compression, refer to COMPRESSION, CHECKING .
6. Bolt 
   • Always replace.
   • With a washer.
   • Follow the sequence when loosening, refer to Fig 3.
   • Tightening sequence and specification, refer to Fig 4.
7. O-ring 
   • Always replace.
   • Lubricate with engine oil.
8. Plug 
   • 5 Nm
   • With a ball head for the engine cover.
9. Cap 
   • With a gasket.
10. O-ring 
    • No replacement part available.
11. Plug 
    • Always replace.
    • Lubricate the O-ring with engine oil.
12. Bracket 
13. Bolt 
    • 9 Nm
14. Heat Shield 
15. Bolt 
    • 20 Nm
16. Bolt 
    • 20 Nm
17. to the Intake Manifold/Turbocharger 
18. Ventilation Pipe 
19. O-ring 
    • No replacement part available.
20. Gasket 
    • No replacement part available.
21. Engine Cover 
22. Bolt 
    • Tightening sequence, refer to Fig 2.
23. Crankcase Ventilation 
    • Observe the sequence for tightening, refer to Fig 2.
24. to the Intake Manifold 
25. Gasket 
    • No replacement part available.
26. Gasket 
    • Replace if damaged.
27. Vacuum Pump 
    • Removing and installing, refer to VACUUM PUMP .
28. Bolts (M6 x 70) 
    • 9 Nm
29. Bolt 
    • 9 Nm
    • Only available for engine code CBFA.
30. Secondary Air Injection Solenoid Valve -N112- 
    • Only available for engine code CBFA.
31. Gasket 
    • Always replace.
    • Only available for engine code CBFA.
32. Retaining Plate 
33. Bolt 
    • 9 Nm
34. Connecting Piece 
35. O-ring 
    • Always replace.
    • Lubricate with coolant.
36. Bolt 
    • 25 Nm
37. Transport Strap 
38. Bolt 
    • 9 Nm
39. Camshaft Position Sensor -G40- 
    • With a O-ring.
    • Lubricate the O-ring with engine oil before installing.
40. Partition Plate 

Fig 2: Identifying Crankcase Ventilation - Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special Tools And Workshop Equipment Required 

• Torque Wrench (5-50 Nm) V.A.G 1331

Procedure 

-- Tighten the crankcase ventilation bolts in sequence -1 through 10- to 11 Nm.

Fig 3: Identifying Cylinder Head - Loosening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Procedure 

-- Remove the bolts -arrows-.

-- Loosen the cylinder head bolts in sequence -1 through 5-.

Fig 4: Identifying Cylinder Head - Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special Tools And Workshop Equipment Required 

• Torque Wrench (5-50 Nm) V.A.G 1331

Procedure 

-- Tighten the new cylinder head bolts in 3 passes in sequence -1 through 5- Using a TORX® bit as follows:

-- Tighten the new bolts -1 through 5- to 40 Nm.

-- Tighten the bolts an additional 90° (1/4) turn.

-- Tighten the bolts an additional 90° (1/4) turn.

-- Then, tighten the new bolts -arrows- to 8 Nm.

-- Then, tighten the bolts -arrows- an additional 90° (1/4) turn.

Fig 5: Identifying Check Of Cylinder Head For Distortion

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special Tools And Workshop Equipment Required 

• Straight Edge 500 mm VAS 6075
• Feeler Gauge

Procedure 

-- Check the cylinder head at several locations for distortion using the straight edge 500 mm VAS 6075 and a feeler gauge.

• Max. permissible distortion: 0.05 mm