Volkswagen Golf Variant / Jetta. Manual - part 383

 

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Volkswagen Golf Variant / Jetta. Manual - part 383

 

 

mission 02Q; Rep. Gr.  34 .

Vehicles with DSG

®

 transmission:

• Tightening specification. Refer to ⇒  6-Speed Dual Clutch

Transmission 02E; Rep. Gr.  34 .

Tightening Specifications:
• 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

 .

Note

Electrical connections and routing. Refer to ⇒  Electrical Equip‐

ment; Rep. Gr.  97 .

– Observe the notes after connecting the Battery - A- . Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Dis‐

connecting and Connecting .

– Fill with coolant. Refer to

⇒ “1.9 Coolant, Draining and Filling”, page 209

 .

– Fill the fuel system. Refer to

⇒ “3.9 Fuel System, Filling/Bleeding”, page 328

 .

1.7.2

Cylinder Head, Removing and Installing, Engine Codes CBDA, CBDB and

CEGA

1. Cylinder Head    

115

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-

116

5-50Nm - VAG1331-

♦ Torque Wrench 1332

40-200Nm - VAG1332-

♦ Shop Crane - Drip Tray -

VAS6208-

♦ Engine Bung Set -

VAS6122- (not illustrated)

DANGER!

♦ 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.

1. Cylinder Head    

117

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

⇒ “3.3 Turbocharger with Exhaust Manifold, Removing and

Installing, Engine Codes CBDA, CBDB, CEGA”, page 279

 .

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 - Front Exhaust Pipe with Particulate Filter. Refer to

⇒ “2.1 Overview - Front Exhaust Pipe with Particulate Filter”,

page 388

 .

Overview - EGR Components. Refer to

⇒ “4.1 Overview - Exhaust Gas Recirculation System Com‐

ponents”, page 403

 .

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.

Removing

WARNING

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.

– Disconnect the battery ground cable when the ignition is

switched off. Refer to ⇒  Electrical Equipment; Rep. Gr.  27 ;

Battery; Battery, Disconnecting and Connecting .

– 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

 .

118

 

 

 

 

 

 

 

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