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Volkswagen Workshop Service and Repair Manuals

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Installing > < Removing and installing cylinder head

Golf Mk4

Removing
Removing
Prerequisites
The engine must be no more than warm to touch.
  Note
Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain radio code first if necessary.
–  With the ignition switched off, disconnect battery earth strap.
–  Remove upper part of intake manifold → Chapter.
–  Loosen or separate the following components:
t  High tension leads terminal 4 from ignition coils.
t  Earth strap from ignition coils.
   
–  Turn crankshaft in engine DOR at securing bolt of vibration damper to TDC no. 1 cylinder marking -arrow-.
–  Drain coolant → Chapter.
–  Remove cylinder head cover.
  WARNING
Fuel system is under pressure! Wear protective glasses 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.
  N13-0135
–  Pull off fuel return line -2- (blue marking) and fuel supply line -1- (white marking).
  Note
To do this, press down buttons on hose couplings.
–  Seal lines so that fuel system is not contaminated by dirt.
–  Separate connector to injectors and pull vacuum hose off fuel pressure regulator.
–  Loosen hose clips and pull coolant hoses off coolant thermostat housing.
–  Now remove thermostat housing.
–  Then remove continued coolant circulation pump -V51- from its bracket. Coolant hoses can remain connected.
–  Pull 3-pin connector off Hall sender -G40-, sender remains installed.
–  Now remove ignition coils.
–  Now unscrew brackets and camshaft cover part.
  A10-0140
–  Counterhold camshafts using AF 24 mm open-jaw spanner to loosen camshaft chain sprockets.
–  Remove front exhaust pipe from exhaust manifold.
  N15-0157
–  Loosen socket head bolts in prescribed sequence and then remove completely.
–  Carefully lift cylinder head off.
  N15-0172

Installing > < Removing and installing cylinder head