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Home >> Volkswagen >> 2003 >> GTI Base, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 148 (1.9L - Cylinder Head, VALVETRAIN - Engine Code(S): BKC, BLS, BRM & BXE (A5 Platform)) >> 15 Engine - Cylinder Head, VALVETRAIN >> Description And Operation >> Cylinder Head Assembly Overview

Cylinder Head Assembly Overview

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

When using an exchanged cylinder head with camshaft installed, the contact surfaces between the lifters and cam lobes must be lubricated before installing the cylinder head cover.

The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.

When cylinder head is replaced, all coolant must also be replaced.

Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the tears have a width of max. 0.5 mm.

Do not mill the valve seats in the cylinder head; only grinding of the valves is permissible.

After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).

After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Always replace gaskets and seals.

Fig 1: Identifying Cylinder Head Assembly Overview
GWWN15-10387Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Toothed belt cover, upper 
  2. Toothed belt 
    • Mark direction of rotation before removing
    • Check for wear
    • Do not kink
    • Removing and installing, tensioning TOOTHED BELT .
  3. 10 Nm 
    • Replace
  4. 25 Nm 
  5. 100 Nm 
  6. Camshaft sprocket 
  7. Hub 
    • With sensor wheel
    • Use counter-holder T10051 to loosen and tighten
    • To remove, use pulling fixture T10052
    • Removing and installing CAMSHAFT .
  8. Toothed belt cover, rear 
  9. Grommet 
    • Replace if damaged
  10. Camshaft Position (CMP) sensor -G40- 
    • For camshaft position
    • To remove, remove grommet from rear of toothed belt cover, refer to "Grommet" in item:  9
  11. Stud bolt 
    • 15 Nm
  12. Cylinder head bolt 
    • Follow sequence for loosening and tightening CYLINDER HEAD .
    • Place washers into cylinder head before installing, refer to "Washer" under:  4
  13. Fuel return line 
  14. Fuel supply line 
  15. Coolant line 
  16. Cylinder head cover 
    • Always clean sealing surfaces of cylinder head with a clean cloth before setting in place
  17. Pressure regulator valve 
    • For crankcase ventilation
  18. To turbocharger 
  19. Cap 
    • Replace gaskets if damaged
  20. Sealing sleeve 
    • Replace if damaged
  21. 10 Nm 
  22. Cylinder head cover gasket 
    • Only replace together with cylinder head cover
    • Before installing, seal contact surfaces with sealant, black AMV 174 004 01 for transmission housing CYLINDER HEAD COVER .
  23. 20 Nm 
  24. Lifting eye 
  25. Pump injector unit 
  26. 10 Nm 
  27. Central harness connector 
    • For pump-injector unit
  28. From brake booster 
  29. Tandem pump 
    CAUTION:

    Pay attention to the notes when reinstalling a running tandum pump TANDEM PUMP => Installing

  30. Supply hose 
  31. Return hose 
  32. Gasket 
    • Replace
  33. Bracket 
  34. Bolt 
  35. Cylinder head 
    • Removing and installing CYLINDER HEAD .
    • After replacing replace entire amount of coolant
  36. Cylinder head gasket 
    • Replace
    • Observe identification Fig 3
    • After replacing replace entire amount of coolant
  37. Glow plug/ceramic glow plug 
  38. Tensioning roller 
  39. 20 Nm + 45° ( 1  / 8  turn) additional turn 
Fig 2: Identifying Check Of Cylinder Head For Distortion
GWWV15-0673Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required 

Max. permissible distortion: 0.05 mm

NOTE:

Remanufacturing diesel cylinder heads is not permitted.

Fig 3: Identifying Cylinder Head Gasket Identification
GWWA15-0105Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

Depending on piston projection, varying cylinder head gasket thicknesses can be installed. When replacing a head gasket, install a head gasket with the same identification.

When installing new pistons or working with a partial motor, check the piston position at TDC PISTON POSITION AT TDC, CHECKING .

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