Cylinder Head

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Drip Tray V.A.G 1306 or VAS 6208
Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Spring Type Clip Pliers VAS 5024 A
Polydrive Bit and Drive Socket T10070 or 3452
Ignition Coil Puller T40039
Silicone Sealant D 174 003 A2

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 fluid and vacuum) and electrical wiring 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

-- Drain the coolant, refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .

-- Remove the engine cover with air filter. Refer to ENGINE COVER WITH AIR FILTER .

-- Remove the battery and the battery tray. Refer to Removal and Installation .

WARNING:

Hot steam may escape when opening the expansion tank cap.

Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
Cover the cap with a cloth and open very carefully.

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

-- Install the transport strap to the cylinder head again in order to better hold the cylinder head during removal.

-- Remove the chain compartment cover. Refer to CHAIN COMPARTMENT COVER .

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

-- Lock the camshafts and remove the adjuster and sprocket from the camshafts. Refer to VALVE TIMING, ADJUSTING .

-- Hold the timing chain -A- as shown to be able to lay it under the adapter -arrow-.

Fig 1: Identifying Timing Chain Held To Lay It Under Pipe Connection

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the 4 exhaust manifold to front exhaust pipe nuts -2- and the exhaust system suspended mount bolts -3-.

Fig 2: Identifying Nuts, Bolts & Front Exhaust Pipe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front exhaust pipe -1- from the manifold and secure it firmly to the side. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

NOTE:

The flex joint in the front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.

-- Disconnect the harness connector for the heated oxygen sensor -G39- at the bulkhead.

-- Remove the wire bracket -3- bolts -arrows- at the Secondary Air Injection (AIR) valve or sealing cap (engines without a AIR system).

Fig 3: Identifying Harness Connectors To Disconnect And Remove Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the cylinder head bolts in the sequence specified.

Fig 4: Identifying Cylinder Head Bolts Removed In Sequence Specified

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the bolt -2- was not able to be pulled out using a magnet, loosen the bolts for the camshaft clamp T40070 one rotation, slide the camshaft clamp T40070 toward the right front (seen in direction of travel) and tighten the bolts again.

A second mechanic is required to remove and install the cylinder head.

-- Carefully remove the cylinder head.

Installing

NOTE:

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

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

Handle the new gasket with extreme care. Damaging will lead to leaks.

Replace the cylinder head bolts.

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

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

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

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

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).

Fig 5: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Note the shelf life date.

-- Apply a bead of sealant -1- (front and rear) onto the clean sealing surfaces as illustrated.

Fig 6: Identifying Sealant Bead Locations

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The sealant bead must be 2.0 to 2.5 mm thick.

-- Install the new cylinder head gasket -2-.

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

Fig 7: Identifying Centering Pins In Cylinder Block

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Apply a bead of sealant -3- (rear only), as illustrated, onto the cylinder head gasket.

Fig 8: Identifying Sealant Bead Locations

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The sealant bead must be 2.0 to 2.5 mm thick.

NOTE:

The cylinder head must be installed within 5 minutes of being applied with sealant.

-- Install the cylinder head.

-- Guide the timing chain over the adapter.

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

-- Then, tighten the cylinder head bolts -1 through 12- in the sequence shown as follows:

Fig 9: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Step	Tighten
1	-- Using a torque wrench, tighten the bolts to 40 Nm.
2	-- Using a ratchet, tighten the bolts an additional 90° (1/4) turn.
3	-- Using a ratchet, tighten the bolts an additional 90° (1/4) turn.

-- Then, tighten the bolts -13- to 10 Nm.

-- Wipe off any sealant, which has leaked out.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

-- Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt.

-- Install the battery tray and battery. Refer to Removal and Installation .

-- Fill with new coolant. Refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .