VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing cylinder head

Special tools and workshop equipment required
   
Socket -3410-
Removing
  Note
Fit all heat shield sleeves in the same place when installing.
–  Remove camshaft housing → Chapter.
–  Remove intake manifold → Chapter.
 

Removing and installing cylinder head

–  Separate electrical connectors:
1 -  On oil pressure switch for reduced oil pressure -F378-
2 -  On fuel pressure sender -G247-
3 -  At injectors
 

Removing and installing cylinder head

–  Unscrew bolt -2- and remove screw-type clip.
–  Remove bolt -1- and nuts -arrows- and tie up catalytic converter.
 

Removing and installing cylinder head

–  Unscrew bolts -arrows- and remove heat shield for right drive shaft.
 

Removing and installing cylinder head

–  Remove heat-shield sleeve.
–  Disconnect electrical connector -arrow- on oil pressure switch -F1-.
 

Removing and installing cylinder head

–  Unscrew bolts -arrows- and detach oil supply pipe -1- and oil return pipe -2-.
 

Removing and installing cylinder head

–  Separate electrical connectors:
1 -  For coolant temperature sender -G62-
2 -  For charge pressure positioner -V465-
 

Removing and installing cylinder head

–  Unscrew bolt -1- from engine support.
 

Removing and installing cylinder head

–  Loosen cylinder head bolts in the sequence -1 … 10- and unscrew them.
–  Take off cylinder head and set it down on a soft surface (foam plastic).
Installing
  Note
Avoid damage to sealing surfaces.
Carefully remove sealant residue from cylinder head and cylinder block.
Ensure that no long scores or scratches are made on the surfaces.
Avoid damage to cylinder block.
No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
Carefully remove remains of emery and abrasives.
Do not remove new cylinder head gasket from packaging until it is ready to be fitted.
Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket.
  Note
Renew bolts that are tightened with specified tightening angle.
Renew self-locking nuts as well as gaskets, seals and O-rings.
When installing a replacement cylinder head, the contact surfaces between hydraulic compensation elements, roller rocker fingers and cams must be oiled before installing the camshaft housing.
Secure all hose connections with the same type of hose clips as original equipment → Electronic Parts Catalogue.
Do not reuse coolant which has been drained off.
 

Removing and installing cylinder head

–  Fit cylinder head gasket -1-.
Note centring pins in cylinder block -arrows-.
Check installation position of cylinder head gasket. Characteristic: the part number should be legible from the inlet side.
–  If crankshaft is turned in the meantime, position piston of No. 1 cylinder at TDC and turn crankshaft back slightly.
–  Fit cylinder head.
–  Insert cylinder head bolts and hand-tighten.
–  Tighten bolts for cylinder head → Fig..
  Note
After repair work it is not necessary to retighten the cylinder head bolts.
Further installation steps are carried out in the reverse order; note the following:
–  Install camshaft housing → Chapter.
–  Install intake manifold → Chapter.
–  Change engine oil → Booklet.
–  Replenish coolant → Chapter.
Specified torques
→ Fig. „“Engine support - specified torque and installation sequence”“
→ Chapter „Assembly overview - cylinder head“
→ Chapter „Assembly overview - turbocharger“
→ Rep. gr.24
→ Fig. „“Installing catalytic converter - tightening torque and sequence”“
→ Running gear, axels, steering; Rep. gr.40
 

Removing and installing cylinder head

Assembly overview - camshaft housing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA
1 -  Bolt Specified torque and tightening sequence → Fig. 2 -  Inlet camshaft control valve 1 -N205- ...

Removing and installing camshaft housing
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Removing and installing headlight dipped beam bulb (dual halogen headlights)
  Note Left headlight dipped beam bulb -M29- and right headlight dipped beam bulb -M31- are only fitted on dual halogen headlights. Removal and installation are described for the left side. Removal and installati ...

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