Volkswagen Golf Variant / Jetta. Manual - part 375

 

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Volkswagen Golf Variant / Jetta. Manual - part 375

 

 

1

Cylinder Head

⇒ “1.1 Overview - Cylinder Head Cover”, page 83
⇒ “1.2 Overview - Cylinder Head”, page 85
⇒ “1.3  Camshaft Position Sensor G40 , Removing and Installing”,

page 87
⇒ “1.4 Engine Cover, Removing and Installing”, page 90
⇒ “1.5 Cylinder Head Cover, Removing and Installing”,

page 90
⇒ “1.6 Toothed Belt, Removing, Installing and Tensioning”, page

95
⇒ “1.7 Cylinder Head, Removing and Installing”, page 103
⇒ “1.8 Vacuum Pump, Removing and Installing”, page 126
⇒ “1.9 Compression, Checking”, page 127

1.1

Overview - Cylinder Head Cover

1 - Bolt

❑ 5 Nm

2 - Bolt

❑ 22 Nm

3 - Protective Strip

❑ For the rail element

(high pressure reser‐

voir) and high pressure

lines

4 - Rail Element (High Pres‐

sure Reservoir)

❑ With high pressure lines
❑ Do not change the an‐

gles of the high pressure

lines

❑ Refer to

⇒ “3.3 Overview - Fuel

System”, page 311

 .

Overview - Fuel System

5 - Bolt

❑ 5 Nm

6 - Fuel Injector Cover
7 - Nut

❑ 10 Nm

8 - Tensioning Claw

❑ Replace
❑ Note the installation po‐

sition Refer to

⇒ Fig. ““Tensioning

Bracket Installation Po‐

sition”“ , page 314

 .

1. Cylinder Head    

83

⇒ “3.3 Overview - Fuel System”, page 311

 .

10 - Bracket

❑ For wiring harness

11 - Vacuum Hose

❑ Check for secure fit and kink free routing
❑ To the Wastegate Bypass Regulator Valve - N75-

12 - Cylinder Head Cover

❑ Removing and installing. Refer to 

⇒ “1.5 Cylinder Head Cover, Removing and Installing”, page 90

 .

13 - Seal

❑ Replace if damaged or leaking

14 - Bolts

❑ 10 Nm
❑ Observe the sequence for loosening and tightening . Refer to

⇒ “1.5 Cylinder Head Cover, Removing and Installing”, page 90

 , Cylinder Head Cover, Removing and

Installing

15 - Cap

❑ Replace the seal if damaged.

16 - Heat Shield
17 - Bushing

❑ For the rail element (high pressure reservoir) - mounting
❑ Replace if damaged

84

Overview - Cylinder Head

1 - Cylinder Head

❑ Observe the notes. Re‐

fer to 

⇒ page 94

 .

❑ Checking for distortion.

Refer to

⇒ Fig. ““Cylinder Head,

Checking for Distor‐

tion”“ , page 86

 .

❑ Removing and instal‐

ling. Refer to

⇒ “1.7 Cylinder Head,

Removing and Instal‐

ling”, page 103

 .

❑ All of the coolant must

be replaced after instal‐

ling

❑ Compression Pressure,

Checking. Refer to

⇒ “1.9 Compression,

Checking”, page 127

 .

2 - Washer

❑ For the cylinder head

bolt

3 - Cylinder Head Bolt

❑ Observe the sequence

for loosening and tight‐

ening . Refer to

⇒ “1.7 Cylinder Head,

Removing and Instal‐

ling”, page 103

 , Cylin‐

der Head, Removing

and Installing

❑ Before installing, insert

washers -item 2-

⇒ Item 2 (page 85)

 into

cylinder head

4 - Bolt

❑ 25 Nm

5 - Lifting Eye
6 - Seal

❑ Replace

7 - Vacuum Pump

DANGER!

Do not disassemble the

vacuum pump under any

circumstances  because

it can cause the vacuum

component  to  malfunc‐

tion. The result would be

brake booster failure.

❑ Removing and installing. Refer to 

⇒ “1.8 Vacuum Pump, Removing and Installing”, page 126

 .

8 - Bolt

❑ 10 Nm

1. Cylinder Head    

85

❑ Coolant Hose Connection Diagram. Refer to 

⇒ “1.3 Coolant Hose Connection Diagram”, page 197

 .

10 - Bolt

❑ 10 Nm

11 - Seal

❑ Replace

12 - Bolt

❑ 25 Nm

13 - Lifting Eye
14 - Cylinder Head Gasket

❑ Replace
❑ Observe the identification. Refer to 

⇒ Fig. ““Cylinder Head Gasket Identification”“ , page 87

 .

❑ All of the coolant must be replaced after replacing

15 - Camshaft Position Sensor - G40-

❑ For camshaft position

16 - Bolt

❑ 10 Nm

Cylinder Head, Checking for Distortion

Special tools and workshop equipment required
♦ Straight Edge - 500mm - VAS6075-
♦ Feeler Gauge
Procedure
– Check the cylinder head in several places for distortion using

a Straight Edge and a feeler gauge.

• Maximum permitted distortion: 0.10 mm.

86

 

 

 

 

 

 

 

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