Volkswagen Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Adapter -10 - 222 A /8-

t	Bracket -T10358-

t	Torque wrench (40 … 200 Nm) -V.A.G 1332-

t	Torque wrench (5 … 50 Nm) -V.A.G 1331-

t	Wing compensation plate -T10311- (Golf Plus only)

Removing –  Release pressure in high-pressure area → Chapter.   WARNING The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar). Prior to opening the high-pressure area, the fuel pressure in the high-pressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on releasing pressure in the high-pressure section → Chapter. Remove following components: t  Removing and installing bottom valve timing housing → Chapter. t  Removing and installing top valve timing housing → Chapter. t  Removing and installing top ancillary bracket → Chapter. t  Removing and installing turbocharger → Chapter. t  Removing and installing intake manifold → Chapter. Golf, Golf Plus, Touran –  Push 2 spindles with hooks onto support bracket -10 - 222 A-.

–  Fit support bracket -10 - 222 A- with adapter -10 - 222 A /8- as shown. Polo –  Position adapter -10 - 222 A /8- on vehicle front end -arrows- as shown.

–  Hook in hooks at left lifting eye.

–  Unscrew front securing bolt for gearbox and attach bracket -T10358- as shown. –  Attach hook of support bracket -10 - 222 A- to bracket -T10358- as shown. –  Turn spindles until the hooks are lightly tensioned. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant → Chapter. –  Observe rules for cleanliness → Chapter.

–  Separate fuel supply line -1- and line to activated charcoal filter -2-. Press release tabs to do this.   WARNING Fuel supply lines are under pressure! Wear eye protection 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. Only Golf, Golf Plus, Golf Cabriolet

–  Remove hose -1- from activated charcoal filter system solenoid valve 1 -N80- to activated charcoal filter. –  Unscrew securing bolts -2- and pull activated charcoal filter upwards. All vehicles

–  Open spring-type clips and pull coolant hoses -1- and -2- off. –  Push catch -3- underneath coolant hoses and pull hoses upwards. –  Put down coolant hoses to rear. –  Remove thermostat housing from cylinder head. Golf, Golf Plus, Touran, Golf Cabriolet

–  Unbolt engine side of assembly mounting from above -arrows-. –  Remove assembly mounting and unscrew engine support. Polo –  Unbolt earth wire -1-.   Caution Nut -2- must not be loosened.

–  Unscrew securing bolts -arrows- for engine mounting. –  Remove complete engine mounting. All vehicles

–  Unhook hook -1- from left lifting eye and push spindle onto left side of support bracket -10 - 222 A-. –  Remove cylinder head → Chapter. –  Remove roller rocker fingers together with support elements and lay aside on a clean surface. –  Ensure that roller rocker fingers and support elements are not interchanged.

–  Loosen cylinder head bolts in sequence given and then remove completely. –  Carefully remove cylinder head. Installing

Specified torque of non-return valve -arrow-: 7 Nm Prerequisite l  The pistons must not be positioned at TDC.   Note t  Do not remove new cylinder head gasket from its packing until immediately before installing. t  Handle new gasket with extreme care. Damage will cause leakage. –  Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. –  Now carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100). –  Carefully remove metal particles, emery residue and cloths. –  Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly. –  Fit new cylinder head gasket. Inscription (Part No.) must be readable. –  Fit cylinder head. When doing this, observe centring pins in cylinder block. –  Insert new cylinder head bolts and tighten hand-tight.

–  Tighten cylinder head bolts in tightening sequence as follows: –  Tighten all bolts to 40 Nm. –  Then turn all bolts 90° further using a rigid wrench. –  Then turn all bolts 90° further again. –  Install supporting elements in cylinder head and fit respective roller rocker finger onto respective valve stem end or supporting element. –  Install cylinder head cover → Chapter –  Adjust valve timing → Chapter. Further assembly is basically the reverse of the dismantling sequence.