volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Installing > < Removing and installing cylinder head
Removing
Removing
l  The engine must be no more than warm to touch.
  WARNING
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
t  Route all types of line (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
t  Ensure that there is sufficient clearance to all moving or hot components.
  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.
–  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.
–  Drain coolant → Chapter.
–  Remove upper part of intake manifold → Chapter.
  Note
Seal intake ports in the lower part of intake manifold using a clean cloth.
  WARNING
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
–  Pull the fuel supply line (white mark) off the fuel rail and place the wiring harness down forwards.
–  Seal lines so that fuel system is not contaminated by dirt.
–  Remove the connections with coolant hoses.
–  Remove secondary air pump intake and pressure lines.
–  Remove bracket of pressure line.
–  Unbolt secondary air pump motor -V101- and bracket and remove.
–  Pull off the following connectors:
t  For secondary air pump motor -V101-
t  For injectors (unclip cable guide)
t  For spark plugs (with assembly tool -T10029-)
–  Unbolt front exhaust pipe with catalytic converter and manifold support.
–  Remove poly V-belt → Chapter.
–  Remove poly V-belt tensioner.
–  Remove toothed belt guard - upper part.
   
–  Turn crankshaft to set camshaft belt pulley to TDC of cylinder no. 1. Marking on camshaft belt pulley must align with arrow on toothed belt guard.
–  Release tensioning roller and remove toothed belt from camshaft belt pulley.
–  Turn crankshaft back slightly.
–  Remove cylinder head cover.
–  Remove rear toothed belt guard upper bolt.
  A13-0077
–  Loosen socket head bolts in specified sequence and then remove completely.
  Note
Use special wrench, long reach -T10070- for polydrive cylinder head bolts.
–  Carefully lift cylinder head off.
  N15-0026

Installing > < Removing and installing cylinder head