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-
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-
Ignition Coil Puller -T40039-

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

The engine must be no more than warm to touch.

NOTE:

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

Change the engine oil if it is dirty. Refer to GENERAL INFORMATION .

-- See if a coded radio is installed. If so, obtain the antitheft code.

-- Turn off the ignition and disconnect the battery ground cable. Refer to Removal and Installation .

GTI and Eos:

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

Continuation for all Vehicles:

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

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Remove the right front part of the wheel housing liners.

Fig 1: Identifying Right Front Part Of Wheel Housing Liners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Fig 2: Identifying Charge Air Hose From Charge Air Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 3: Identifying Charge Air Pipe Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect all electrical lines from the turbocharger and set aside.

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 5: Identifying Oil Return Line

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

Fig 6: Identifying Bolts And Support For Turbocharger

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the battery, battery tray bolts -arrows- and tray.

Fig 7: Identifying Battery Holder Bolts

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

Fig 8: Identifying Coolant Hoses

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

-- Remove the wire bracket bolt -arrow- and move the wiring harness on its side.

Fig 9: Identifying Cable Bracket Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the coolant connection bolts -arrows-.

Fig 10: Identifying Coolant Flange Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

-- Remove the locking pin -T10060 A- from the ribbed belt tensioner.

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

With a divided toothed belt guard, refer to TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD .
Without a divided toothed belt guard, refer to TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD .

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

-- Follow the sequence -1 through 10- for loosening the cylinder head bolts.

Fig 11: Identifying Cylinder Head Bolts Loosening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

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

-- 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 so that no dirt or abrasive powder can get between the cylinder wall and piston.

-- 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.

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

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

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

Fig 12: Identifying Cylinder Block Centering Pins

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the cylinder head.

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

-- Then, tighten the cylinder head bolts -1 through 10- in the sequence shown as follows:

Fig 13: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, 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.

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

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

With a divided toothed belt guard, refer to TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD .
Without a divided toothed belt guard, refer to TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD .

Further installation is in the reverse order of removal.

Fill with new coolant. Refer to DRAINING AND FILLING .