Volkswagen Golf Variant / Jetta. Manual - part 382

 

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Volkswagen Golf Variant / Jetta. Manual - part 382

 

 

Note

A second technician is needed when removing the cylinder

head.

The toothed belt tensioning roller is pulled off the stud bolt

when prying the cylinder head out.

The oil return pipe on the turbocharger is pulled out of the

support when removing the cylinder head.

Make sure all necessary lines are loosened.

– Lift the cylinder head first on the transmission side and guide

it out of the rear toothed belt guard. Be careful not to let the

toothed belt tensioning roller fall.

– Lay the cylinder head down so that the oil return pipe is not

bent. Place a wooden block under the exhaust manifold if nec‐

essary.

Installing

Caution

There is a risk of damaging sealing surfaces:

♦ Carefully remove the sealant residue from the cylinder

head and cylinder block.

♦ Make sure that no long grooves or scratches result.

Risk of damaging the cylinder block:

♦ There must be no oil or coolant in the blind holes for the

cylinder head bolts in the cylinder block.

Risk of the cylinder head gasket leaking:

♦ Carefully remove all lapping and sanding residue.
♦ Only unpack the new cylinder head gasket immediately

before installing.

♦ To prevent the cylinder head gasket silicone layer and re‐

cessed area from being damaged, always handle the seal

extremely carefully.

Risk of damaging open valves:

♦ If a replacement cylinder head is installed, only remove

the accompanying plastic base immediately before instal‐

ling to protect the open valves.

Risk of damaging valves and piston heads after working on the

valvetrain:

♦ To ensure valves do not strike pistons when starting, care‐

fully rotate engine at least two full revolutions.

♦ Before installing, check if the oil return pipe decoupling

element is bent or stretched. If this is the case, there could

be micro tears which could result in leaks. If necessary,

replace the oil return pipe before installing the cylinder

head.

1. Cylinder Head    

111

Always replace cylinder head bolts.

Replace gaskets, seals and self-locking nuts and clamps.

Carefully remove residual sealant from cylinder head and cyl‐

inder block. Make sure that no long grooves or scratches

result. When using sand paper, grit must not be below 100.

Thoroughly remove all sanding and lapping residue.

Only unpack the new cylinder head gasket immediately before

installing.

– Before mounting the cylinder head, remove the Crankshaft

Stop - T10050- and rotate the crankshaft back opposite the

direction of engine rotation until all of the pistons are nearly

even under TDC.

– Place the cylinder head gasket with the identification upward.

– To center, slide the Guide Tool - Cylinder Head - 3070- into

the outer holes on the intake side.

Note

The tensioning roller must be placed on the stud bolt when mount‐

ing the cylinder head.

– Install the cylinder head, insert the eight cylinder head bolts

and tighten them by hand.

– Remove the Guide Pin using the Pin Remover from the Guide

Tool - Cylinder Head - 3070- through the bolt holes and insert

the cylinder head bolts.

– Tighten the cylinder head in the tightening sequence, in four

stages as follows:

1 - Tighten Using Torque Wrench:
Step I = 35 Nm
Step II = 60 Nm
2 - Tighten Further Using a Solid Wrench:
Step III = 

1

/4 (90 °) turn

Step IV = 

1

/4 (90 °) turn

– Secure the toothed belt guard on the back of the cylinder head.
• Tightening specification -item 14- 

⇒ Item 14 (page 44)

 .

– Install the hub and the camshaft sprocket. Refer to

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

 , Cam‐

shafts, Removing and installing.

– Secure the camshaft and the high pressure fuel pump with the

Diesel Injection Pump Locking Pin - 3359- .

112

and secure the crankshaft with the Crankshaft Stop - T10050- .

– Installing and tensioning the toothed belt. Refer to

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

page 95

 .

The Additional Numbered Procedures Must Be Followed to En‐

sure the Particulate Filter with the NOx Reduction Catalytic Con‐

verter Is Installed without Tension:

Note

After installing the particulate filter with NOx reduction catalytic

converter, make sure it is not under stress.

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

clamps.

Caution

There is a risk of damaging the decoupling element between

the  particulate  filter  and  NOx  reduction  catalytic  converter.

When removing and installing:

♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling element.

1.

Position the lower bracket with the nuts on the cylinder block

and on the particulate filter. (Do not tighten the nuts.)

2.

Position the new clamp with a new gasket between the par‐

ticulate filter and turbocharger (do not tighten the clamp):

• Make sure the clamp is in the correct installation position. Re‐

fer to

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

alytic Converter”, page 360

 .

3.

Install the EGR filter -item 9- 

⇒ Item 9 (page 399)

 .

4.

Position a new clamp between the particulate filter and EGR

filter (do not tighten the clamp):

• Make sure the clamp is in the correct installation position. Re‐

fer to

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

alytic Converter”, page 360

 .

5.

Position the particulate filter on the upper bracket with the

bolt. (Do not tighten the bolt.)

– Tighten the mounting elements in the following sequence:
6.

Clamp between the particulate filter and turbocharger.

7.

Lower bracket to the cylinder block:

8.

Lower bracket to the particulate filter:

9.

Upper bracket to the particulate filter:

10. Upper bracket to the cylinder head:
11. Clamp between the particulate filter and EGR filter:

1. Cylinder Head    

113

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

alytic Converter”, page 360

 .

Further installation is the reverse order of removal. Note the fol‐

lowing:
• The self-locking nuts and seals must be replaced.
• Position the charge air pipe connecting hose before securing

the turbocharger.

• Pay attention to the installation position of the Exhaust Gas

Temperature Sensor 1 - G235- .

• Replace the banjo bolt with the turbocharger support gaskets

as well as the oil return pipe O-rings.

• Do not stretch the oil return pipe decoupling element when

installing the turbocharger support.

• Make sure the line connections are secure.
– Install the cylinder head cover. Refer to

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

page 90

 .

114

 

 

 

 

 

 

 

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