Cylinder Head

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Drip tray VAG 1306 or VAS 6208
Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332
Spring type clip pliers VAS 5024A
Polydrive bit and drive socket T 10070 or polydrive key 3452
Ignition coil puller T 40039

CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

When loosening the cylinder head bolts, the engine must be no more than warm to the touch. Otherwise, the cylinder head may warp.

NOTE:

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

Perform a oil change if the engine oil is contaminated

-- Release the high side fuel pressure. Refer to HIGH SIDE FUEL PRESSURE, RELEASING .

-- Determine whether a coded radio is installed. If necessary, obtain the antitheft code.

-- With the ignition off, disconnect the battery cable. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Remove the plenum chamber bulkhead. Refer to Description and Operation .

-- Remove the intake manifold. Refer to INTAKE MANIFOLD .

-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- Remove the front part of the right wheel housing liner. Remove bolts -1 through 3- to do so.

Fig 1: Identifying Right Front Part Of Wheel Housing Liners

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-- Remove the catalytic converter with front exhaust pipe. Refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

-- Remove the charge air hose -arrow- from the charge air cooler.

Fig 2: Identifying Charge Air Hose From Charge Air Cooler

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-- Remove the charge air pipe bolts -arrows- and disconnect the charge air pipe.

Fig 3: Identifying Charge Air Pipe Bolts

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-- Disconnect all electrical connectors from turbocharger and set aside.

-- Remove the oil supply line and coolant supply line bolts -arrows- from the turbocharger.

Fig 4: Identifying Oil Supply Line And Coolant Supply Line At Turbocharger

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-- Remove the oil return line bolts -arrows- from the turbocharger.

Fig 5: Identifying Oil Return Line

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-- Remove the turbocharger support bolts -1 and 2- and remove the support for the turbocharger.

Fig 6: Identifying Bolts And Support For Turbocharger

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-- Remove battery and battery holder. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Remove the cover -1- for the E-box and remove the wire -2-.

Fig 7: Identifying Cover Of E-Box, Wire & Bolts

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-- Remove the battery holder bolts -arrows- and remove the battery holder.

-- Disconnect the coolant hoses -1 and 2-.

Fig 8: Identifying Coolant Hoses

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-- Remove the nut -1- and remove the ground wire.

Fig 9: Identifying Ground (GND) Wire & Connector

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-- Disconnect the electrical connector -2-.

-- Disconnect all electrical connectors required from the cylinder head and set aside.

-- Remove the wire bracket bolt -arrow- and set the wiring harness aside.

Fig 10: Identifying Cable Bracket Bolt

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-- Remove the coolant flange bolts -arrows-.

Fig 11: Identifying Coolant Flange Bolt

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-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Remove the T 10060A from the ribbed belt tensioner.

-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Mark the hoses -1 through 3- to the lines.

Fig 12: Identifying Fuel Supply Line Hoses

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WARNING:

The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.

-- Open the spring clamps for lines -1 through 3- and disconnect the hoses.

-- Remove the toothed belt, refer to one of the following:

-- Follow sequence for loosening the cylinder head bolts.

Fig 13: Identifying Cylinder Head Bolts Loosening Sequence

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NOTE:

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

-- Remove the cylinder head.

Installing

NOTE:

The bores in the engine block for the cylinder head bolts must be free of oil and coolant.

Only remove the new cylinder head gasket from its packing immediately before installing.

Handle the new gasket with extra care. Damage to the silicon layer and recessed area lead to leakage.

Replace the cylinder head bolts.

Always replace self locking nuts and bolts during assembly work.

Always replace bolts that are secured with tightening specifications as well as O-rings and gaskets.

After installing a replacement cylinder head with the camshaft installed, oil the contact surfaces between the roller cam followers and cam lubricating surfaces after installing the cylinder head.

-- Insert clean cloths into the cylinders so that no dirt or abrasive powder can get between cylinder wall and piston.

-- Do not allow dirt or abrasive powder to get into coolant either.

-- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper below 100 grit).

-- Carefully remove metal particles, emery remains and cloths.

-- In the event the crankshaft has been rotated in the meantime: Set the cylinder 1 piston to Top Dead Center (TDC) and turn the crankshaft back again slightly.

-- Install the new cylinder head gasket. Text (replacement part number) must be visible.

-- Note the alignment pins in the cylinder block -arrows-.

Fig 14: Identifying Cylinder Block Centering Pins

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-- Install the cylinder head.

-- Install the cylinder head bolts and tighten them hand tight.

-- Tighten the cylinder head bolts in the sequence shown as follows:

Fig 15: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tightening sequence	Nm
1	-- Tighten to 40 Nm.
2	-- Using a ratchet, tighten an additional 90° (¹ /₄ turn).
3	-- Using a ratchet, tighten an additional 90° (¹ /₄ turn).

-- Install the cylinder head cover. Tightening sequence, refer to Figure.

-- Install the toothed belt, refer to one of the following:

-- Install battery holder and bolts -arrows-.

Fig 16: Identifying Cover Of E-Box, Wire & Bolts

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-- Route the wire -2- as shown in the illustration and secure it to the E-box -1-.

The rest of the assembly is basically a reverse of the removal sequence.

-- Install the battery and follow the necessary measures after connecting the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Fill the cooling system. Refer to DRAINING AND FILLING .