volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Installing > < Removing and installing cylinder head

Golf Mk5

Removing
Removing
–  With ignition switched off, disconnect earth strap from battery. → Electrical system; Rep. gr.27.
   
–  Remove engine cover.
To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.
Golf Plus
–  Remove plenum chamber bulkhead. → General body repairs, exterior; Rep. gr.50.
Continuation for all vehicles
  N10-0451
–  Remove air filter housing with air mass meter and connecting pipe.
Remove bolt -arrow A- and pull air filter housing upwards out of mounting.
–  Remove battery.
–  Remove insulation tray → General body repairs, exterior; Rep. gr.50.
–  Drain coolant → Chapter
–  Disconnect fuel supply and return lines as well as coolant line on cylinder head.
–  Before removing cylinder head, extract fuel from tandem pump using hand-operated vacuum pump -V.A.G 1390- and water drainage container -V.A.G 1390/1- → Chapter.
–  Pull fuel filter module upwards out of bracket and lay it with hoses to side.
–  Remove poly V-belt → Chapter.
–  Remove connecting pipe between air charge cooler and turbocharger.
  N10-0436
–  Separate vibration damper and remove it from crankshaft. Lock crankshaft at TDC No. 1 cylinder using crankshaft stop -T10050 bzw. T10100- → Chapter.
Vehicles with no particulate filter:
–  Disconnect front exhaust pipe from turbocharger, loosen double clamp and slide exhaust pipe back → Chapter.
Vehicles with particulate filter:
–  Unscrew mountings for particulate filter and clamp on turbocharger and push diesel particulate filter to side → Chapter.
Continuation for all vehicles:
–  On vehicles with four-wheel drive remove the bevel box to reach the threaded connection for turbocharger support → 6-speed manual gearbox; Rep. gr.34.
–  Remove turbocharger support and oil return from turbocharger.
–  Loosen tensioning roller securing nut and release tension on toothed belt.
–  Remove tensioning roller securing nut.
–  Remove hubs for camshaft pulleys → Chapter.
–  Separate Hall sender -G40- → Item on cylinder head.
–  Remove securing bolts between rear toothed belt guard and cylinder head.
–  Unbolt bracket for vacuum reservoir and dipstick.
–  Remove exhaust gas recirculation connecting pipe → Item.
–  Remove oil supply line for turbocharger → Chapter.
–  Pull off or disconnect all other electrical connections as necessary from cylinder head and lay to one side.
–  Separate all connection, coolant, vacuum and intake hoses from cylinder head.
–  Remove cylinder head cover → Chapter.
–  Remove rocker arm shaft and inner securing bolts for retaining frame → Fig..
  N15-0701
–  Maintain sequence when loosening cylinder head bolts.
–  Lift cylinder head slightly and remove from engine laterally past toothed belt guard.
  Note
t  The toothed belt tensioning roller remains on the engine support.
t  The cylinder head must be guided carefully to prevent damage.
  N15-0026

Installing > < Removing and installing cylinder head