Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Drip Tray (V.A.G 1306) or (VAS 6208)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Spring Type Clip Pliers (VAS 5024 A)
• Polydrive Bit and Drive Socket (T10070) or (3452)
• Ignition Coil Puller (T40039)
• Silicone Sealant (D 174 003 A2)
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
Removing
- Drain the coolant, refer to one of the following:
• Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to => [ Draining and Filling ] Procedures.
• Jetta from MY 11, refer to => [ Draining and Filling ] Procedures.
- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover with Air Filter.
- Remove the battery and the battery tray.
Hot steam may escape when opening the expansion tank cap.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Cover the cap with a cloth and open very carefully.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Install the transport strap to the cylinder head again in order to better hold the cylinder head during removal.
- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Chain Compartment Cover.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Lock the camshafts and remove the adjuster and sprocket from the camshafts. Refer to => [ Valve Timing, Adjusting ] Adjustments.
- Hold the timing chain - A - as shown to be able to lay it under the adapter - arrow -.
- Remove the 4 exhaust manifold to front exhaust pipe nuts - 2 - and the exhaust system suspended mount bolts - 3 -.
- Remove the front exhaust pipe - 1 - from the manifold and secure it firmly to the side. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe with Catalytic Converter.
• The flex joint in the front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.
- Disconnect the harness connector for the heated oxygen sensor (G39) at the bulkhead.
- Remove the wire bracket - 3 - bolts - arrows - at the Secondary Air Injection (AIR) valve or sealing cap (engines without a AIR system).
- Remove the cylinder head bolts in the sequence specified.
• If the bolt - 2 - was not able to be pulled out using a magnet, loosen the bolts for the camshaft clamp (T40070) one rotation, slide the camshaft clamp (T40070) toward the right front (seen in direction of travel) and tighten the bolts again.
• A second mechanic is required to remove and install the cylinder head.
- Carefully remove the cylinder head.
Installing
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Only remove the new cylinder head gasket from its packaging immediately before installing.
• Handle the new gasket with extreme care. Damaging will lead to leaks.
• Replace the cylinder head bolts.
- Insert clean cloths into the cylinders and chain compartment so that no dirt or abrasive powder can penetrate between the cylinder wall and piston and into the chain compartment.
- Do not allow dirt or abrasive powder to get into the coolant either.
- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
- Carefully remove any metal particles, emery remains and the cloths.
- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).
Note the shelf life date.
- Apply a bead of sealant - 1 - (front and rear) onto the clean sealing surfaces as illustrated.
• The sealant bead must be 2.0 to 2.5 mm thick.
- Install the new cylinder head gasket - 2 -.
- Note the alignment sleeves in the cylinder block - arrows -.
- Apply a bead of sealant - 3 - (rear only), as illustrated, onto the cylinder head gasket.
• The sealant bead must be 2.0 to 2.5 mm thick.
• The cylinder head must be installed within 5 minutes of being applied with sealant.
- Install the cylinder head.
- Guide the timing chain over the adapter.
- Install the cylinder head bolts and tighten them hand tight.
- Then, tighten the cylinder head bolts - 1 through 12 - in the sequence shown as follows:
- Then, tighten the bolts - 13 - to 10 Nm.
- Wipe off any sealant, which has leaked out.
The rest of the installation follows the reverse of the removal procedures. When doing this note the following:
- Remove the locking pin (T40069) from the rear of the cylinder block and install the locking bolt.
- Install the battery tray and battery.
- Fill with new coolant. Refer to one of the following:
• Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to => [ Draining and Filling ] Procedures.
• Jetta from MY 11, refer to => [ Draining and Filling ] Procedures.