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Removing and installing engine cover panel > < Cylinder head

Golf Mk5

Assembly overview - cylinder head
Assembly overview - cylinder head
  Note
t  Renew cylinder head bolts.
t  When reassembling, renew self-locking nuts and bolts that are tightened by turning through to a specified angle as well as oil seals and gaskets.
t  The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.
t  When fitting a new cylinder head or cylinder head gasket, drain off all the old coolant and refill with new coolant.
   
1 - Cylinder head gasket
q   Renew.
q   Observe installation position: Part number to cylinder head
2 - Bolt
q   25 Nm
3 - Transport bracket
4 - Bolt
q   Tightening sequence → Fig..
5 - Cylinder head
q   Removing and installing → Chapter
q   Check for distortion → Fig..
6 - Cylinder head bolt
q   Renew.
q   Note sequence when loosening → Fig..
q   Note correct sequence when tightening → Fig..
7 - O-ring
q   Renew.
q   Lubricate with engine oil
8 - Plug
q   5 Nm
q   With ball head for engine cover panel
9 - Cap
q   With seal
10 - O-ring
q   Renew.
q   Lubricate with engine oil
11 - Plug
12 - Bracket
13 - Bolt
q   9 Nm
14 - Heat shield
15 - Bolt
q   20 Nm
16 - Bolt
q   20 Nm
17 - To intake hose/turbocharger
18 - Breather pipe
19 - O-ring
q   No replacement part available
20 - Seal
q   No replacement part available
21 - Engine cover
22 - Bolt
q   Tightening sequence → Fig..
23 - Crankcase breather
q   Note correct sequence when tightening → Fig..
24 - To intake manifold
25 - Seal
q   No replacement part available
26 - Seal
q   Renew if damaged.
27 - Vacuum pump
q   Removing and installing → Chapter
28 - Securing bolts for vacuum pump
q   Engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA: 9 Nm
q   Engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB: 8 Nm + additional 180° turn
29 - 9 Nm
q   Only engine code CBFA
30 - Secondary air inlet valve -N112-
q   Only engine code CBFA
31 - Seal
q   Only engine code CBFA
q   Renew.
32 - Retaining plate
33 - Bolt
q   9 Nm
34 - Connection
35 - O-ring
q   Renew.
q   Lubricate with coolant
36 - Bolt
q   25 Nm
37 - Transport bracket
38 - Bolt
q   9 Nm
39 - Hall sender -G40-
40 - Partition

   
Crankcase breather system - tightening torque
–  Tighten bolts for crankcase breather in the sequence -1 … 10- to 11 Nm.
  A15-10605
Loosening cylinder head bolts
–  Undo and remove bolts -arrows-.
–  Undo cylinder head bolts in the sequence -1 … 5-.
  A15-10474
Bolt tightening sequence for cylinder head
–  Tighten cylinder head bolts in the sequence -1 … 5- as follows:
1.  Tighten initially to 40 Nm using torque wrench.
2.  Use fixed wrench to turn 90° further.
3.  Use fixed wrench to turn 90° further.
4.  Pre-tighten bolts -arrows- to 8 Nm.
5.  Turn bolts -arrows- 90° further using a fixed wrench.
  A15-10475
Checking cylinder head for distortion
–  Use straight edge 500 mm -VAS 6075- and feeler gauge to measure cylinder head for distortion at several points.
t  Max. permissible distortion: 0.05 mm
  V15-0654

Removing and installing engine cover panel > < Cylinder head