Volkswagen Workshop Service and Repair Manuals

Removing and installing cylinder head cover Special tools and workshop equipment required

t  Spring-type clip pliers -VAS 5024A-

t  Torque wrench -V.A.G 1331- t  Puller -T10095 A- Removing   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  To avoid damage to lines, ensure sufficient clearance to all moving or hot components. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  With ignition switched off, disconnect earth strap from battery. –  All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. –  Remove engine cover. –  Remove air cleaner → Chapter. –  Remove intake hose and intake connecting flange between air mass meter and throttle valve module → Chapter. –  Pull off connecting hose of crankcase breather between cylinder head cover and intake hose on cylinder head cover.   Note To do this, press down buttons on hose couplings. –  Remove ignition coils with output stages using puller -T10095 A-.

–  Unclip wiring harness of ignition coils out of cable guide -arrows-. –  Unclip coolant hose -1-, breather line of activated charcoal filter system -2- and vacuum line -3- on intake manifold.

–  Pull off 6-pin connector on throttle valve module -arrow-.   WARNING Steam may escape when expansion tank is opened. Wear protective glasses and 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. –  Pull off coolant hoses from throttle valve module and seal hose ends.

–  Unscrew earth connection from wiring harness bracket -arrow-.   WARNING Fuel system is under pressure! Wear protective glasses and gloves to avoid injuries and skin contact. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

–  Pull off fuel supply line -1- (with white marking) and fuel return line -2- (with blue marking) off fuel rail and catch fuel that escapes in a cloth. –  Seal lines so that fuel system is not contaminated by dirt.

–  Unscrew cable guide for fuel lines, breather line of activated charcoal filter system and wiring harness on cylinder head cover -arrows-.

–  Now pull vacuum lines -arrows- off intake manifold.   Note To do this, press down buttons on hose couplings. –  Unclip pressure hose between combination valve and secondary air pump motor and all other lines from retainers on intake manifold and cylinder head cover. –  Unscrew cable guide for coolant hoses and wiring harness on cover part → Item. –  Pull vacuum hose off intake manifold changeover vacuum actuator. –  Remove the two bolts on the side for the intake manifold support. –  Pull connectors off thermal switch and radiator fan. –  Remove front bumper: → General body repairs, exterior; Rep. Gr.63 –  Bring lock carrier into service position → General body repairs, exterior; Rep. Gr.50. –  Unscrew dipstick guide tube from intake manifold. –  Unscrew securing bolts of intake manifold and remove intake manifold together with throttle valve module. –  Remove intake manifold and place it on a suitable surface so that the vacuum actuator will not be damaged.   Note Seal intake ports in intake manifold and in cylinder head with clean cloths. –  Remove cylinder head cover. Installing Installation is carried out in the reverse order. When installing, note the following:   Note t  Replace cylinder head cover if damaged or leaking. t  Bolt intake manifold first to cylinder head. Then tighten both bolts of intake manifold support. t  Ensure that fuel hoses are tight. –  If necessary fill with coolant → Chapter. Torque settings

Threaded connection		Torque setting
Cylinder head cover to cylinder head		8 Nm
Intake manifold to cylinder head		13 Nm
Intake manifold to support		23 Nm
Dipstick guide tube to intake manifold		8 Nm