Cylinder Head

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

When installing a replacement cylinder head, all of the contact surfaces between the hydraulic lash adjusters, roller rocker arms and cam running surfaces on the camshaft must be lubricated before installing the cylinder head cover.

Only remove the plastic protectors installed to protect the open valves immediately before fitting the cylinder head.

Replace the cylinder head bolts.

When replacing the cylinder head or cylinder head gasket, the coolant must be completely replaced.

Special tools and workshop equipment required

Drip Tray for VAS 6100 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 6499
Polydrive Bit and Drive Socket T10070
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 all lines and wires in their original locations.
Make sure there is enough clearance to moving or hot components to prevent damage to the lines.

Removing

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

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

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

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

Fig 1: Identifying Battery Holder & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -arrows- and remove the battery tray from the vehicle.

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 back onto the cylinder head in order to better hold the cylinder head during removal.

-- Remove the timing chain cover. Refer to TIMING CHAIN COVER .

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

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

-- Hold the timing chain -A- as shown, so it can be routed below the coolant pipe connection -arrow-.

Fig 2: Holding Timing Chain To Be Able To Lay It Under Pipe Connection

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-- Remove the 4 exhaust pipe with catalytic converter to exhaust manifold nuts -2- and the suspended mount bolts -3-.

Fig 3: Identifying Front Exhaust Pipe, Nuts & Bolts

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-- Remove the exhaust pipe with catalytic converter -1- from the manifold and tie it up firmly to the side. Refer to EXHAUST PIPE WITH CATALYTIC CONVERTER .

NOTE:

The coupling element in the exhaust pipe with catalytic converter must not be bent more than 10°, otherwise it may be damaged.

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

-- Remove the wire bracket -3- bolts -arrows- at the Secondary Air Injection (AIR) valve.

Fig 4: Disconnecting Harness Connectors And Removing Bracket

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

Fig 5: Cylinder Head Bolts Removal Sequence

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NOTE:

If the bolt -2- cannot be removed with a magnet, loosen the camshaft clamp T40070 bolts one turn. Slide the camshaft clamp T40070 forward and to the right and tighten the bolts again.

A second technician 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 cylinder bores 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 scratching 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 6: 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) on the clean sealing surfaces as shown.

Fig 7: Sealant Bead Locations

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The sealant bead must be 2.0 to 2.5 mm thick.

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

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

Fig 8: Identifying Centering Pins In Cylinder Block

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

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 coolant pipe connection.

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

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

Fig 9: Cylinder Head Bolts Tighten Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

The rest of the installation follows the reverse of the removal procedure. Note the following:

Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt.
Replace and fill the coolant. Refer to COOLANT, DRAINING AND FILLING .
Install the battery. Refer to Removal and Installation .