Volkswagen Golf Variant / Jetta. Manual - part 376

 

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Volkswagen Golf Variant / Jetta. Manual - part 376

 

 

Remanufacturing diesel cylinder heads is not permitted.

Cylinder Head Gasket Identification
♦ Part number = -arrow 1-
♦ Holes = -arrow 2-
♦ Control code = -arrow 3- (ignore this!)
♦ Installed position: the identification mark faces up.

Note

Depending on piston projection, varying cylinder head gasket

thicknesses can be installed. When replacing a gasket, install

a gasket with the same identification -arrow 3-.

Determine the piston position at TDC when installing new pis‐

tons or a partial engine. Refer to

⇒ “3.5 Piston Projection in Top Dead Center (TDC), Check‐

ing”, page 72

 .

1.3

Camshaft Position Sensor - G40- , Re‐

moving and Installing

– Remove the engine cover. Refer to

⇒ “1.4 Engine Cover, Removing and Installing”, page 90

 .

– Remove the fuel filter and the Auxiliary Fuel Pump - V393- .

Refer to

⇒ “6.6  Auxiliary Fuel Pump V393 (Inline Fuel Pump), Remov‐

ing and Installing”, page 259

 .

– Disconnect the connector from the Engine Coolant Tempera‐

ture Sensor on Radiator Outlet - G83- .

– Open the clamps -arrows- and remove the toothed belt guard.
– Remove the right front wheel housing liner.
– Remove the ribbed belt. Refer to

⇒ “1.4 Ribbed Belt, Removing and Installing”, page 47

 .

– Remove the vibration damper -item 29- 

⇒ Item 29 (page 45)

 .

1. Cylinder Head    

87

belt sprocket with the Crankshaft Stop - T10050- . Push the

crankshaft stop from the front side of the toothed belt sprocket

into the splines. The camshaft toothed segment must be in the

»12 o'clock« position.

Note

The markings on the crankshaft toothed belt sprocket -2- and the

Crankshaft Stop - T10050- -1- must align. The pin on the Crank‐

shaft Stop - T10050- must engage in the hole on the sealing

flange.

– Loosen the camshaft sprocket bolts -1-.

– Loosen the coolant pipe bolt -1- and then the bolts for the high

pressure pump toothed belt sprocket -2-.

– Loosen the tensioning roller nut -1- and turn the tensioning

roller eccentric pulley with the Wrench - Tensioning Roller -

T10264- counter-clockwise in direction of -arrow-, until the

tensioning roller can be locked with the Tensioning Roller

Locking Tool - T10265- .

88

rection of -arrow- all the way and tighten the nut -1- by hand.

– Remove the toothed belt from the idler roller and the high

pressure pump.

– Disconnect the connector for the Camshaft Position Sensor -

G40- -arrow-.

– Disconnect from the retainer.

– Remove the Camshaft Position Sensor - G40- -arrow-.
– Remove the ribs with a screwdriver and remove the cover for

the opening -arrows-.

– Remove the Camshaft Position Sensor - G40- from the cylin‐

der head and guide its connector through the opening in the

toothed belt guard.

Installing
Install in reverse order of removal. Note the following:
♦ Seal the opening in the toothed belt guard with a rubber plug.

Refer to the Parts Catalog.

– Mount the toothed belt and adjust the valve timing. Refer to

⇒ , page 98

 .

1. Cylinder Head    

89

Engine Cover, Removing and Installing

Removal
– Pull the engine cover at the corners in direction of -arrows-

upward out of the mounting points with a jerking motion.

Installing

Caution

Make sure the four fasteners (ball sockets) are positioned cor‐

rectly before installing the engine cover. Move them back into

their position, if necessary. Otherwise the engine cover could

be damaged.

– Press the engine cover ball sockets into the correct installation

position if necessary.

– Position the engine cover on the mounting points and press

the corners into the retainers.

1.5

Cylinder Head Cover, Removing and In‐

stalling

Note

When replacing the cylinder head or cylinder head gasket, all

of the coolant must be replaced.

Cylinder heads with cracks between the valve seats can con‐

tinue to be used without reducing service life, as long as the

tears have a width of maximum 0.5 mm.

After working on the valvetrain and engine, carefully rotate by

hand at least two full turns to be sure that valves do not strike

pistons when starting.

Always replace the self-locking nuts, seals, gaskets and

clamps.

Overview - Cylinder Head Cover. Refer to

⇒ “1.1 Overview - Cylinder Head Cover”, page 83

 .

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Hose Clip Pliers - VAS6362-

90

 

 

 

 

 

 

 

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