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

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Engine cylinder head, valve gear / Cylinder head / 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

Removing – Remove coolant pump → Chapter. – Remove air filter housing →&nbs ...

Other materials:

Undercoated areas, body overview indicating differing coat thicknesses
Note Undercoating (stone-chipping protection) applied during repair work must be identical in appearance and thickness to the original undercoating. Water drainage holes must remain clear. All threaded studs and welded nuts with metric ...

Removing and installing turbocharger
Special tools and workshop equipment required Engine bung set -VAS 6122- Hose clip pliers -VAS 6362- ...

Fuse tables for fuses in the engine compartment
Fig. 231 Engine compartment: fuse layout First read and observe the introductory information and safety warningsThe table shows the fuse locations for the items of electrical equipment which are most relevant to the customer. The left column contains the location, the other columns contain ...