Volkswagen Workshop Service and Repair Manuals

Installing cylinder head   Note t  There must be no oil or coolant in the cylinder head bolt pockets in the cylinder block. t  Do not remove new cylinder head gasket from its packing until immediately before installing. t  Handle new gasket with extreme care. Damage will cause leakage. t  Renew cylinder head bolts. –  Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. –  Also prevent dirt and emery cloth particles from getting into coolant. –  Now carefully clean sealing surfaces of cylinder head and cylinder block. When doing this, ensure that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100). –  Carefully remove metal particles, emery residue and cloths. –  If crankshaft is turned in the meantime, position piston of No. 1 cylinder at TDC and turn crankshaft back slightly. –  Fit new cylinder head gasket. Lettering (Part No.) must be readable.

–  Observe centring pins in cylinder block -arrows-. –  Fit cylinder head. –  Insert cylinder head bolts and tighten hand-tight.

–  Then tighten cylinder head bolts in indicated sequence as follows:

Stage	Tighten
1	–  Tighten to 40 Nm using torque wrench.
2	–  Turn 90° (1/4 turn) further using rigid spanner.
3	–  Turn 90° (1/4 turn) further using rigid spanner.

–  Install cylinder head cover → Chapter. Engine code AXW: Continuation for engine codes BLR, BLX, BLY, BVX, BVY, BVZ → Anchor.

–  Pull off connector -1-. Remove coolant expansion tank and lay it to side. Golf:

–  Fit engine support bracket -10-222A- with adapters -10-222A/13- and take up weight of engine in installation position. Touran:

–  Fit engine support bracket -10-222A- with adapters -10-222A/22- and take up weight of engine in installation position. Continuation for all vehicles:

–  Remove securing bolts from assembly mounting/engine bracket -arrows- and remove complete assembly mounting.   Caution When raising engine using support bracket -10-222A-, ensure that no components or hoses are damaged, strained or torn off.

–  Raise engine with support bracket -10-222A- until both upper bolts -2 and 3- of engine bracket can be loosened and removed. –  Remove noise insulation → General body repairs, exterior; Rep. Gr.50.

–  Set camshaft pulley to TDC marking by turning crankshaft. The marking on camshaft toothed belt pulley must align with arrow on toothed belt guard.

–  Remove lower bolt -1- and remove engine bracket downwards.

–  Remove bolts from centre part of toothed belt guard -arrows- and remove toothed belt guard from engine. Continuation for all vehicles: –  Install toothed belt and adjust valve timing:    Engine code AXW → Chapter    Golf without split toothed belt guard (BLR, BLX, BLY, BVX, BVY, BVZ) → Chapter.    Touran without split toothed belt guard (BLR, BLX, BLY, BVX, BVY, BVZ) → Chapter.    Golf with split toothed belt guard (BVX, BVY, BVZ) → Chapter    Touran with split toothed belt guard (BVX, BVY, BVZ) → Chapter –  Install poly V-belt → Chapter. –  Observe required procedures after connecting battery → Electrical system; Rep. Gr.27. –  Fill coolant system with coolant → Chapter. –  Connect vehicle diagnostic, testing and information system -VAS 5051 B-. –  Read all fault memories and clear all fault entries that have been created during assembly.   Note If the fault memory was cleared, the readiness code must be generated → Vehicle diagnosis, testing and information system VAS 5051“Guided functions”.