volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Installing > < Removing and installing cylinder head

Golf Mk4

Removing
Removing
   
–  Remove fuse No. 28 (fuel pump) from fuse holder.
–  First remove main drive toothed belt → Chapter.
  WARNING
Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully.
–  Open and close expansion tank cap to release pressure in cooling system.
–  Drain coolant → Chapter.
  WARNING
Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
  N24-0588
–  Disconnect fuel supply and return lines and lines to activated charcoal filter system solenoid valve 1 -N80-, items -1-, -2- and -3-.
–  Seal lines so that fuel system is not contaminated by dirt.
–  Observe rules for cleanliness → Chapter.
–  Remove upper part of intake manifold → Chapter.
  Note
Seal intake ports in lower part of intake manifold with a clean cloth.
–  Remove camshaft housing → Chapter.
–  Remove roller rocker fingers together with support elements and lay aside on a clean surface.
–  Ensure that roller rocker fingers and support elements are not interchanged.
–  Remove oil dipstick guide tube.
–  Remove securing bolt for toothed belt rear guard (near right-hand lifting eye).
–  Remove thermostat housing from cylinder head.
–  Pull clamp securing coolant pipe to coolant pump off thermostat housing.
–  Unbolt line guide from lower part of intake manifold.
–  Pull off or disconnect all other electrical connections as necessary from engine and lay to side.
–  Unbolt starter catalytic converter from exhaust manifold.
  N15-0546
–  Now the engine must be lifted again slightly with spindle -B-.
  Note
Both lifting eyes are located on the cylinder head, so an additional bracket must be secured to the cylinder block to support the engine.
–  Attach bracket -T10109- to cylinder block using threaded hole in vicinity of coolant pump, as illustrated. Specified torque: 20 Nm
–  Lift engine slightly using second spindle -A- until spindle -B- is relieved.
–  Remove spindle -B-.
  N15-0490
–  Loosen cylinder head bolts in sequence given and then remove completely.
–  Carefully remove cylinder head.
  N15-0026

Installing > < Removing and installing cylinder head