Volkswagen Eurovan 2000-03

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top front cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove the 3 screws at the top of the front grille.
  14.  
  15. Remove the headlight washer spray tube, if equipped.
  16.  
  17. Carefully pry away the trim frame starting below the headlight.
  18.  
  19. Remove the front grille and the trim frame as a unit.
  20.  
  21. Remove the intake hose between Mass Air Flow (MAF) sensor and the throttle valve control module.
  22.  
  23. Remove the two top bolts on each side that support the lock carrier.
  24.  
  25. Fold the lock carrier forward , along with the radiator assembly.
  26.  
  27. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  28.  
  29. Remove the ignition coils using T10094 extractor.
    1. Remove or disconnect:

      Connector from throttle valve control module.
       
      Coolant hoses from throttle valve control module and plug hose ends.
       
      All vacuum lines at cylinder head.
       
      Center support between intake manifold and heat shield/exhaust manifold.
       
      Pressure hose at combination valve and connecting hose at cylinder head cover.
       
      Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
       
      Intake manifold supports at both sides at bracket from heat shield/exhaust manifold.
       
      Secondary Air Injection (AIR) pump motor.
       
      Dipstick and dipstick tube.
       
      Intake manifold with throttle valve control module.
       
      Cylinder head cover.
       
      Fuel supply and return lines.
       
      Coolant temperature sensor.
       
      All remaining harness connectors and vacuum lines at cylinder head.
       
      Thermostat housing.
       
      Exhaust pipe from exhaust manifold.
       
      Timing chain.
       

    2.  

  30.  
  31. Using Polydrive Special tool 3452, or equivalent, loosen, then remove the cylinder head bolts in the proper sequence.
  32.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt removal sequence-2.8L engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.8L engine


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.

  1. Set the crankshaft and camshaft to TDC for cylinder No. 1.
  2.  
  3. Install or connect:
    NOTE
    Make sure dowel sleeves in cylinder block bore 12 and 20 are inserted and the cylinder head gasket is secured. The longer cylinder head bolts go into the center bores.



    Head gasket, making sure that the part No. faces up.
     



    Cylinder head and tighten the head bolt hand-tight.
     
    New cylinder head bolts in sequence in 4 steps:
     

    1. Tighten all bolts to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten all bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Tighten all bolts an additional 1 / 2 turn (180°), using 2 steps of 90° each.
      NOTE
      It is not necessary to retighten the cylinder head bolts.

    6.  

  4.  
  5. Installation is the reverse of the removal procedure using the following torque values.

    Camshaft roller chain adjusting bolt: 30 ft. lbs. (40 Nm).
     
    Camshaft adjuster: 88 inch lbs. (10 Nm).
     
    Drive belt tensioner bolt: 88 inch lbs. (10 Nm).
     
    Exhaust pipe and exhaust manifold nuts: M8 18 ft. lbs. (25 Nm), M10 30 ft. lbs. (40 Nm).
     
    Intake manifold bolts: 18 ft. lbs. (25 Nm).
     
    Thermostat housing bolt: 88 inch lbs. (10 Nm).
     
    Valve cover bolts: 88 inch lbs. (10 Nm).
     

  6.  
  7. Connect the negative battery cable.
  8.  

2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top front cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove the 3 screws at the top of the front grille.
  14.  
  15. Remove the headlight washer spray tube, if equipped.
  16.  
  17. Carefully pry away the trim frame starting below the headlight.
  18.  
  19. Remove the front grille and the trim frame as a unit.
  20.  
  21. Remove the intake hose between Mass Air Flow (MAF) sensor and the throttle valve control module.
  22.  
  23. Remove the two top bolts on each side that support the lock carrier.
  24.  
  25. Fold the lock carrier forward , along with the radiator assembly.
  26.  
  27. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  28.  
  29. Remove the ignition coils using T10094 extractor.
    1. Remove or disconnect:
    2.  



    Connector from throttle valve control module.
     
    Coolant hoses from throttle valve control module and plug hose ends.
     
    All vacuum lines at cylinder head.
     
    Center support between intake manifold and heat shield/exhaust manifold.
     
    Pressure hose at combination valve and connecting hose at cylinder head cover.
     
    Unclip pressure hose and all other lines from retainers at intake manifold and at cylinder head cover.
     
    Intake manifold supports at both sides at bracket from heat shield/exhaust manifold.
     
    Secondary Air Injection (AIR) pump motor.
     
    Dipstick and dipstick tube.
     
    Intake manifold with throttle valve control module.
     
    Cylinder head cover.
     
    Fuel supply and return lines.
     
    Coolant temperature sensor.
     
    All remaining harness connectors and vacuum lines at cylinder head.
     
    Thermostat housing.
     
    Exhaust pipe from exhaust manifold.
     
    Timing chain.
     

  30.  
  31. Using Polydrive Special tool 3452, or equivalent, loosen, then remove the cylinder head bolts in the proper sequence.
  32.  

To install:



Click image to see an enlarged view

Fig. Cylinder head bolt removal sequence-2.8L engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.8L engine


NOTE
The bolt holes in the engine block MUST be clean and free of debris and fluid. Always replace the cylinder head bolts.

  1. Set the crankshaft and camshaft to TDC for cylinder No. 1.
  2.  
  3. Install or connect:

    Head gasket, making sure that the part No. faces up.
     

  4.  


NOTE
Make sure dowel sleeves in cylinder block bore 12 and 20 are inserted and the cylinder head gasket is secured. The longer cylinder head bolts go into the center bores.



Cylinder head and tighten the head bolt hand-tight.
 
New cylinder head bolts in sequence in 4 steps:
 
Tighten all bolts to 22 ft. lbs. (30 Nm).
 
Tighten all bolts to 37 ft. lbs. (50 Nm).
 
Tighten all bolts an additional12
 


NOTE
It is not necessary to retighten the cylinder head bolts.

  1. Installation is the reverse of the removal procedure using the following torque values.
    1. Camshaft roller chain adjusting bolt: 30 ft. lbs. (40 Nm).
    2.  
    3. Camshaft adjuster: 88 inch lbs. (10 Nm).
    4.  
    5. Drive belt tensioner bolt: 88 inch lbs. (10 Nm).
    6.  
    7. Exhaust pipe and exhaust manifold nuts: M8 18 ft. lbs. (25 Nm), M10 30 ft. lbs. (40 Nm).
    8.  
    9. Intake manifold bolts: 18 ft. lbs. (25 Nm).
    10.  
    11. Thermostat housing bolt: 88 inch lbs. (10 Nm).
    12.  
    13. Valve cover bolts: 88 inch lbs. (10 Nm).
    14.  

  2.  
  3. Connect the negative battery cable.
  4.  

 
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