Cylinder Head Overview

Fig 1: Cylinder Head Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Cylinder Head Gasket
   • Always replace.
   • Note the installed position: The replacement part number must be visible from the intake side.
2. Bolt
   • 25 Nm
3. Transport Strap
4. Bolt
   • Always replace.
   • Follow the sequence when loosening, refer to Fig 3.
   • Tightening sequence and specification, refer to Fig 4.
5. Cylinder Head
   • Check for distortion, refer to Fig 5.
   • Removing and installing, refer to CYLINDER HEAD .
   • Checking compression, refer to COMPRESSION, CHECKING .
6. Bolt
   • Always replace.
   • With a washer.
   • Follow the sequence when loosening, refer to Fig 3.
   • Tightening sequence and specification, refer to Fig 4.
7. O-ring
   • Always replace.
   • Lubricate with engine oil.
8. Plug
   • 5 Nm
   • With a ball head for the engine cover.
9. Cap
   • With a gasket.
10. O-ring
    • No replacement part available.
11. Plug
    • Always replace.
    • Lubricate the O-ring with engine oil.
12. Bracket
13. Bolt
    • 9 Nm
14. Heat Shield
15. Bolt
    • 20 Nm
16. Bolt
    • 20 Nm
17. To The Intake Manifold/Turbocharger
18. Ventilation Pipe
19. O-ring
    • No replacement part available.
20. Gasket
    • No replacement part available.
21. Engine Cover
22. Bolt
    • Tightening sequence, refer to Fig 2.
23. Crankcase Ventilation
    • Observe the sequence for tightening, refer to Fig 2.
24. To The Intake Manifold
25. Gasket
    • No replacement part available.
26. Gasket
    • Replace if damaged.
27. Vacuum Pump
    • Removing and installing, refer to VACUUM PUMP .
28. Bolts (M6 x 70)
    • 9 Nm
29. Bolt
    • 9 Nm
    • Only available for engine code CBFA.
30. Secondary Air Injection Solenoid Valve -N112-
    • Only available for engine code CBFA.
31. Gasket
    • Always replace.
    • Only available for engine code CBFA.
32. Retaining Plate
33. Bolt
    • 9 Nm
34. Connecting Piece
35. O-ring
    • Always replace.
    • Lubricate with coolant.
36. Bolt
    • 25 Nm
37. Transport Strap
38. Bolt
    • 9 Nm
39. Camshaft Position Sensor -G40-
    • With a O-ring.
    • Lubricate the O-ring with engine oil before installing.
40. Partition Plate

Fig 2: Identifying Crankcase Ventilation - Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required 

• Torque Wrench (5-50 Nm) V.A.G 1331

Procedure 

-- Tighten the crankcase ventilation bolts in sequence -1 through 10- to 11 Nm.

Fig 3: Cylinder Head Loosening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Procedure 

-- Remove the bolts -arrows-.

-- Loosen the cylinder head bolts in sequence -1 through 5-.

Fig 4: Cylinder Head Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required 

• Torque Wrench (5-50 Nm) V.A.G 1331

Procedure 

-- Tighten the new cylinder head bolts in 3 passes in sequence -1 through 5- Using a TORX® bit as follows:

-- Tighten the new bolts -1 through 5- to 40 Nm.

-- Tighten the bolts an additional 90° (1/4) turn.

-- Tighten the bolts an additional 90° (1/4) turn.

-- Then, tighten the new bolts -arrows- to 8 Nm.

-- Then, tighten the bolts -arrows- an additional 90° (1/4) turn.

Fig 5: Checking Cylinder Head For Distortion

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required 

• Straight Edge 500 mm VAS 6075
• Feeler Gauge

Procedure 

-- Check the cylinder head at several locations for distortion using the straight edge 500 mm VAS 6075 and a feeler gauge.

• Max. permissible distortion: 0.05 mm