Volkswagen Golf/Jetta/Cabriole 1990-1999

Cylinder Head

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REMOVAL & INSTALLATION





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Fig. Exploded view of a 2.0L cylinder head



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Fig. VR6 cylinder head



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Fig. Lift a stuck gasket with a gasket scraper



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Fig. Typical head gasket

1.8L Engine
  1. Place the lock carrier into the service position as follows:
    1. Remove the front bumper.
    2.  
    3. Tag and remove any wiring or connector that would inhibit locking the carrier.
    4.  
    5. Remove the three quick-release screws on the front noise insulation panel.
    6.  
    7. Unbolt the air guide between the lock carrier and the air filter.
    8.  
    9. If installed, remove the retaining clamps for the wiring harness at the left side of the radiator frame.
    10.  
    11. Remove the No. 2 bolts and install Support 3369 or equivalent.
    12.  
    13. Remove the remaining bolts and pull the lock carrier out to the stop.
    14.  
    15. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    16.  

  2.  
  3. Turn the ignition switch to the OFF position, then disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt, then the engine driven cooling fan.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove the intake manifold.
  10.  
  11. Remove the accessory drive belts.
  12.  
  13. Label and detach the following lines and electrical connectors:

    Wastegate bypass regulator valve
     
    Evaporative Emission (EVAP) canister purge regulator valve
     
    Power outage stage
     
    Mass Air Flow (MAF) sensor
     

  14.  
  15. Remove the air cleaner housing.
  16.  
  17. Detach the Engine Coolant Temperature (ECT) and the temperature II sensor harness connector.
  18.  
  19. Label and detach all connections from the cylinder head and position them aside.
  20.  
  21. Remove the crankcase breather line.
  22.  
  23. Disconnect the fuel supply and return lines.
  24.  
  25. Disconnect the oil supply line at the cylinder head.
  26.  
  27. Remove the exhaust manifold heat shield.
  28.  
  29. Unbolt the turbocharger from the exhaust manifold.
  30.  
  31. Disconnect the coolant hose to the heat exchanger at the rear of the cylinder head.
  32.  
  33. Remove the upper timing belt cover.
  34.  
  35. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at Top Dead Center (TDC).
  36.  
  37. Using a T45 Torx® wrench, loosen the timing belt tensioner.
  38.  
  39. Push down on the tensioner, and remove the belt from the camshaft gear.
  40.  
  41. Remove the Torx® bolt and swing the tensioner assembly bracket forward.
  42.  
  43. Remove the valve cover.
  44.  



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Fig. Cylinder head bolt removal sequence-1.8L engine

  1. Remove the cylinder head bolts in sequence, as shown.
  2.  
  3. Remove the cylinder head, then clean the gasket mating surfaces.
  4.  
  5. Clean and dry out the cylinder head bolt holes.
  6.  

To install:


WARNING
Always replace the cylinder head bolts. Always replace self-locking nuts, bolts, gaskets and O-rings. Do not remove the new head gasket from the package until immediately before installing.

  1. Before installing the cylinder head, be sure NO pistons are at TDC.
  2.  
  3. Loosen the turbocharger support bracket to reduce the likelihood of any tension while installing the cylinder head.
  4.  
  5. Install the head gasket with the part number visible from the intake side.
  6.  
  7. Install the cylinder head.
  8.  
  9. Install the new cylinder head bolts and tighten by hand.
  10.  



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Fig. Cylinder head bolt tightening sequence-1.8L engine

  1. Tighten the new cylinder head bolts in sequence in two steps:
    1. Tighten all of the bolts to 44 ft. lbs. (60 Nm).
    2.  
    3. Tighten all of the bolts an additional 1 / 2 turn (180°).
    4.  

  2.  


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

  1. Using new gaskets, install the turbocharger to the exhaust manifold , coat the bolts with Hot Bolt Paste G 052 112 A3 (or equivalent), then tighten the mounting bolts to 26 ft. lbs. (35 Nm). Tighten the turbo support bracket mounting bolts to 33 ft. lbs. (40 Nm).
  2.  
  3. Install the valve cover.
  4.  
  5. Install the timing belt.
  6.  
  7. Install the accessory drive belts.
  8.  
  9. Install the exhaust manifold heat shield.
  10.  
  11. Connect the oil supply lines to the cylinder head and tighten the retaining straps to 15 ft. lbs. (20 Nm).
  12.  
  13. Install the crankcase breather.
  14.  
  15. Connect the fuel supply and return lines.
  16.  
  17. Attach any items removed during disassembly.
  18.  
  19. Connect the coolant temperature sensors, and install the air cleaner housing.
  20.  
  21. Fill the engine with coolant.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fully close all power windows, operate all window switches for at least one second in the close direction to activate the one-touch opening/closing function
  26.  
  27. Check the oil level before starting the engine
  28.  
  29. Set the clock to the correct time.
  30.  


NOTE
Diagnostic Trouble Codes (DTCs) are stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  
  3. Adjust the headlights.
  4.  

2.0L Engine


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Fig. Using rags or shop towels, plug the ports in the lower intake manifold to prevent foreign objects from entering



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Fig. Align the timing marks before removing any valve train components such as the timing belt



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Fig. It is always a good idea to mark the direction of the timing belt before removal



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Fig. Remove the timing belt once the tensioner has been released



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Fig. The head bolts are located in the sill below the arrow. Caution, many VW models use head bolts with a TORX® head. Use only the proper size tool when removing these bolts



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Fig. A long breaker bar is needed to attain enough leverage to break the head bolts free



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Fig. Once all of the head bolts have been loosened in the proper sequence, remove them and place them in their equivalent position on a marked piece of paper or cardboard



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Fig. Pull the head from the vehicle as shown



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Fig. Remove and inspect the hydraulic lifters



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Fig. The head can be cleaned once it is removed using a parts washer such as this one from SafetyKleen®. If not accessible, your local machine shop should supply such services.

  1. Disconnect the negative battery cable.
  2.  
  3. Open the radiator cap and drain the cooling system.
  4.  
  5. Disconnect the throttle cable. Label and disconnect all wiring and vacuum lines from the intake manifold.
  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Disconnect the fuel supply and return lines.
  10.  
  11. Disconnect the radiator and heater hoses from the cylinder head.
  12.  
  13. Disconnect and label wiring for oil pressure and temperature sensors.
  14.  
  15. Remove the distributor cap and wires.
  16.  
  17. Disconnect the exhaust pipe from the exhaust manifold.
  18.  
  19. if equipped, remove the EGR pipe from the exhaust manifold.
  20.  
  21. Remove the accessory drive belts and any accessory that is bolted to the head.
  22.  
  23. Remove the cylinder head cover, timing belt cover and belt.
  24.  
  25. Loosen the cylinder head bolts in the reverse of the tightening sequence.
  26.  
  27. Remove the bolts and lift the head straight off.
  28.  



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Fig. Tighten the cylinder head bolts in the sequence shown-2.0L (ABA) engine

To install:

  1. Before reinstalling the head, check the flatness of the head and block in both width and length, then diagonally from each corner.
  2.  
  3. Install the new cylinder head gasket with the word TOP or OPEN facing upward; do not use any sealing compound.
  4.  
  5. To align the cylinder head, install Guide Pins from tool 3070, or equivalent, into the holes for cylinder head bolts 8 and 10.
  6.  
  7. Install the cylinder head.
  8.  
  9. Install the cylinder head bolts, except 8 and 10, by hand.
  10.  
  11. Remove the Guide Pins using tool 3070 or equivalent, then install head bolts 8 and 10.
  12.  
  13. Tighten the head bolts in sequence in the following steps:
    1. With a torque wrench: 30 ft. lbs. (40 Nm).
    2.  
    3. With a torque wrench: 44 ft. lbs. (60 Nm).
    4.  
    5. With a standard wrench: 1 / 4 turn (90°).
    6.  
    7. With a standard wrench: an additional 1 / 4 turn (90°).
    8.  

  14.  
  15. Install the camshaft drive belt and adjust the tension.
  16.  
  17. Connect the exhaust pipe to the manifold. Use new gaskets and self-locking nuts and tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Connect the EGR pipe, if equipped.
  20.  
  21. Connect wiring to the oil pressure and temperature sensors.
  22.  
  23. Install the ignition system components.
  24.  
  25. Connect the radiator and heater hoses.
  26.  
  27. Connect the throttle cable and all wiring and vacuum lines.
  28.  
  29. Install the thermostat with a new O-ring. Tighten the housing bolts to 7 ft. lbs. (10 Nm). Refill the cooling system.
  30.  
  31. Install the accessory drive belts and adjust the tension.
  32.  
  33. Install the upper intake manifold.
  34.  
  35. Connect all wiring and vacuum lines disconnected from the intake manifold. Connect the throttle cable.
  36.  
  37. Connect the fuel supply and return lines.
  38.  
  39. Install the battery, if removed. Connect the negative and positive battery cables.
  40.  
  41. Refill and bleed the cooling system.
  42.  
  43. When everything has been properly installed and connected, be sure to change the oil and filter before starting the engine.
  44.  

2.8L VR6

This procedure requires special tool 3268 or equivalent. This is a setting tool that holds the camshafts in the correct position for installing the timing chains. Before removing the cylinder head, be sure new bolts are available. The cylinder head bolts are made to stretch and cannot be used again.

  1. Disconnect the battery cables and remove the battery.
  2.  
  3. Disconnect the wiring and vacuum lines as required to remove the air cleaner, Mass Air Flow (MAF) sensor and duct.
  4.  
  5. Open the radiator cap and remove the drain plug from the coolant pipe below the intake manifold to drain the cooling system.
  6.  
  7. Remove the engine trim cover. Remove the distributor cap, ignition wires and wire guide as an assembly.
  8.  
  9. Disconnect the throttle cable. Label and disconnect the wiring and vacuum lines from the intake manifold and remove the upper manifold.
  10.  
  11. The injectors and fuel rail assembly may be left on the manifold. Disconnect the fuel supply and return lines and the wiring connector for the injectors.
  12.  
  13. Disconnect the radiator and heater hoses.
  14.  
  15. Thread a long 8 x 10mm bolt into the accessory drive belt tensioner to release the tension. Move the tensioner only as required to remove the belt.
  16.  
  17. Remove the alternator and the belt tensioner.
  18.  
  19. Remove the heatshield and the bolts to disconnect the 2 piece exhaust manifold from the engine. Note the position of the gaskets.
  20.  
  21. Remove the distributor and the timing chain tensioner bolt from the timing chain cover.
  22.  
  23. Remove the cylinder head cover, upper timing chain cover and the retaining plate.
  24.  
  25. If possible, rotate the crankshaft to TDC of No. 1 piston. Clean the oil off the chain and sprockets and mark the direction of rotation for assembly.
  26.  
  27. Hold the camshafts at the flats with a 24mm wrench and remove the bolts to remove the sprockets and chain. Note the position of the distributor drive on the short camshaft.
  28.  


WARNING
Do not use the setting tool to hold the camshafts when removing or installing the sprocket bolts. The camshafts and the tool will be damaged.

  1. Carefully check to be sure all necessary wires, hoses and brackets and components have been removed.
  2.  
  3. Loosen the cylinder head bolts in the reverse of the torque sequence. Remove and discard the bolts.
  4.  
  5. Remove the cylinder head.
  6.  

To install:

  1. Carefully clean the old gasket material from the head and the block. Before reinstalling the head, check the flatness of the head and block in both width and length, then diagonally from each corner. Maximum allowable distortion is 0.004 in. (0.1mm).
  2.  
  3. If the new head gasket already has sealant in the small holes at the timing chain end, remove the sealant. Apply a silicone sealer to the timing chain end and install the gasket onto the block with the word TOP or OPEN facing up.
  4.  
  5. Fit the cylinder head over the locating dowels and set the head onto the engine. Install new bolts and hand-tighten them. Do not attempt to re-use the old bolts.
  6.  
  7. Tighten the bolts in sequence as described in the following steps:
    1. Tighten all bolts to 30 ft. lbs. (40 Nm).
    2.  
    3. Tighten all bolts to 44 ft. lbs. (60 Nm).
    4.  
    5. Tighten all bolts an additional 1 / 4 turn (90°).
    6.  
    7. Tighten all bolts an additional 1 / 4 turn (90°).
    8.  

  8.  



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Fig. Be sure to tighten the cylinder head bolts in the sequence shown-2.8L (AAA) engine

  1. Be sure the crankshaft is at TDC on No. 1 piston. Install the setting tool to lock the camshafts in place, then install the timing chain and sprockets. Be sure they are positioned to rotate in the original direction.
  2.  
  3. Hold the camshaft with a 24mm wrench and install the sprocket bolt. Be sure the distributor drive is correctly positioned and tighten the bolts to 74 ft. lbs. (100 Nm).
  4.  
  5. Install the tensioner shoe and temporarily install the upper timing chain cover. Install the tensioner bolt and remove the setting tool. Rotate the crankshaft 4 full turns and stop at TDC of No. 1 piston. The setting tool should fit into the camshafts.
  6.  
  7. Remove the tensioner bolt and upper timing chain cover again. Apply new sealant as required, install the cover and tighten the bolts to 82 inch lbs. (10 Nm). Install the tensioner bolt and tighten to 15 ft. lbs. (20 Nm).
  8.  
  9. Install the cylinder head cover.
  10.  
  11. Use new gaskets and install the intake and exhaust manifolds. Tighten the nuts and bolts to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the alternator belt and adjust tension.
  14.  
  15. Install the accessory drive belt and adjust tension.
  16.  
  17. Connect the radiator and heater hoses.
  18.  
  19. Install the injectors, fuel rail assembly and manifold. Connect the fuel supply and return lines. Connect the wiring connector for the injectors.
  20.  
  21. Install the upper manifold. Tighten the manifold bolts to 18 ft. lbs. (25 Nm).
  22.  
  23. Connect the wiring and vacuum lines disconnected from the intake manifold. Connect the throttle cable.
  24.  
  25. Install the distributor cap, ignition wires and wire guide as an assembly. Install the engine trim cover.
  26.  
  27. Disconnect the battery cables and remove the battery.
  28.  
  29. Refill and bleed the cooling system.
  30.  
  31. When everything has been properly installed and connected, be sure to change the oil and filter before starting the engine.
  32.  

 
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