volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Installing cylinder head > < Removing and installing cylinder head
6-cyl. fuel injection engine Mechanics
Removing and installing cylinder head
Removing and installing cylinder head cover

Removing

  • ‒ Remove spark plug connectors with H.T. cables:

=> Repair group 28; Motronic injection and ignition system; Servicing ignition part

 
N10-0017
  • ‒ → Removing H.T. cable guides -1- and -2-.
  • ‒ Remove cover above intake manifold upper part -3-.
  • ‒ Pull crankcase breather valve off cylinder head cover and breather hose to solenoid valve 1 for active charcoal filter system off intake manifold upper part.

Note:

On vehicles without crankcase breather valve expressly ensure that the fitting position of the activated charcoal filter breather hose is observed (danger of fire) Fig.1 and 2 !

  • ‒ Remove intake hose from throttle valve housing.
  • ‒ Pull connectors off throttle valve potentiometer, heater element, idling stabilization valve and intake manifold temperature sender.
  • ‒ Detach accelerator cable from throttle valve housing and support bracket (do not remove locating clip).
  • ‒ Pull coolant hose off throttle valve housing and seal (first release pressure from cooling system).
  • ‒ Pull vacuum hose off fuel pressure regulator.
  • ‒ Pull vacuum hose off brake servo.
  • ‒ Unclip fuel pipes from cylinder head cover.
  • ‒ Detach dipstick guide tube on intake manifold lower part.
  • ‒ Remove intake manifold upper part (with throttle valve housing).

Note:

Seal intake ports with clean cloth.

  • ‒ Remove cylinder head cover.

Installing

Install in reverse order.

Notes:

  • ◆ Replace cylinder head cover and intake manifold upper part gaskets.
  • ◆ First secure intake manifold upper part to intake manifold lower part, then the two rear supports ( , Pos. 4 and 32 ).
  • ‒ Adjusting throttle cable
  • ‒ If necessary top-up coolant => Page 19-13
 
N20-0020

→ Fig. 1     Fitting position of activated charcoal filter breather hose on intake manifold upper part

Marking on the breather hose must align with the marking on the intake manifold upper part -arrows-.

Attention!
The activated charcoal filter breather hose must not come into contact with other components and must be routed over the crankcase breather hose.
 
N13-0022

→ Fig. 2     Fitting position of the crankcase breather hose on cylinder head cover

The marking on the breather hose must align with the marking on the cylinder head cover -arrows-.

Installing cylinder head > < Removing and installing cylinder head