Volkswagen Golf Variant / Jetta. Manual - part 380

the cylinder head cover correctly.

Note

The camshaft is removed here for clarity.

– Press the toothed belt guard upper section near the clips

-arrows- against the cylinder head cover until the clips engage

with each other. Use a screwdriver to press the guard if nec‐

essary.

– Check the clearance between the hub and the toothed belt

guard upper section.

– Install the right front wheel housing liner. Refer to ⇒  Body

Exterior; Rep. Gr.  66 ; Wheel Housing Liner .

50 ; Noise Insulation .

Further assembly is performed in the reverse order of the remov‐

al. Note the following:
• Route the fuel hoses without kinks.
• Check the fuel hoses for secure fit.
• Do not interchange the supply and return lines (the return line

is blue or has a blue marking, the supply line is white or has a

white marking).

• Clip the fuel hoses back into the retainers.
– Install the Auxiliary Fuel Pump - V393- . Refer to

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

ing and Installing”, page 259

 .

– Install the fuel filter. Refer to

⇒ “6.3 Fuel Filter, Removing and Installing”, page 251

 .

– Install the engine cover. Refer to

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

 .

1.7

Cylinder Head, Removing and Installing

⇒ “1.7.1 Cylinder Head, Removing and Installing”, page 103

 .

1.7.1

Cylinder Head, Removing and Installing

Special tools and workshop equipment required
♦ Guide Tool - Cylinder Head - 3070-
♦ Diesel Injection Pump Locking Pin - 3359-
♦ Crankshaft Stop - T10050-
♦ Counterhold - Camshaft Gear - T10051-
♦ Puller - Camshaft Sprocket - T10052-
♦ Socket - Xzn 10 - T10385-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Engine Bung Set - VAS6122- (not illustrated)

1. Cylinder Head    

103

♦ Follow the safety precautions when working on the diesel

direct fuel injection system. Refer to

⇒ “1 Safety Precautions when Working on Diesel Direct

Fuel Injection System”, page 303

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 305

 .

Always pay attention to these instructions before and during

work.

104

♦

Overview - Toothed Belt Drive. Refer to

⇒ “1.2 Overview - Toothed Belt Drive”, page 43

 .

♦

Overview - Cylinder Head Cover. Refer to

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

 .

♦

Overview - Cylinder Head. Refer to

⇒ “1.2 Overview - Cylinder Head”, page 85

 .

♦

Overview - Turbocharger with Exhaust Manifold and Attach‐

ments. Refer to

⇒ “3.1 Overview - Turbocharger with Exhaust Manifold and

Attachments”, page 270

 .

♦

Overview - Charge Air Cooler Components. Refer to

⇒ “4.2 Overview - Charge Air Cooler Components”,

page 290

♦

Overview - Intake Manifold with Attachments. Refer to

⇒ “3.12 Overview - Intake Manifold with Attachments”,

page 331

 .

♦

Overview - Particulate Filter with NOx Reduction Catalytic

Converter. Refer to

⇒ “1.2 Overview - Particulate Filter with NOx Reduction Cat‐

alytic Converter”, page 360

 .

♦

Overview - EGR Components. Refer to

⇒ “3.1 Overview - Exhaust Gas Recirculation System Com‐

ponents”, page 398

 .

♦

Hose connections are secured with either spring or hose

clamps.

♦

Always replace clamp-type clips with spring-type clips.

♦

Hose Clip Pliers - VAS6362- or the Hose Clip Pliers -

VAS6340- are recommended for installing spring clips.

♦

All cable ties which are opened or cut open when removing

cylinder head, must be replaced in the same position when

installing cylinder head.

♦

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.

Removing

Note

The Battery - A- ground cable must be disconnected for the fol‐

lowing procedure. For this reason check if a coded radio is in‐

stalled. If necessary, obtain anti-theft code beforehand.

1. Cylinder Head    

105

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

– Remove the engine cover. Refer to

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

 .

– Remove the air filter housing. Refer to

⇒ “3.14 Overview - Air Filter”, page 335

 .

Caution

Electronic components could be destroyed when the Battery -

A- is disconnected:

♦ Complete the steps for disconnecting the Battery - A- .

– When the ignition is switched off, disconnect the ground cable

-arrow- from the Battery - A- . Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

– Remove the Battery - A- and the battery tray -arrows-.
– Remove the cylinder head cover. Refer to

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

page 90

 .

– Remove the toothed belt from the camshaft. Refer to

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

page 95

 , Toothed Belt, Removing, Installing and Tensioning.

– Remove the camshaft sprocket and the hub. Refer to

⇒ “2.2 Camshafts, Removing and Installing”, page 131

 , Cam‐

shafts, Removing and installing.

106