Genuine Volkswagen Golf SportWagen Cylinder Head

Volkswagen Golf SportWagen Cylinder Head Parts and Q&A

• Cylinder Head
  04E-103-061-F
  Q: What precautions should be taken regarding the Cylinder Head when disconnecting the battery and performing engine work for 5-cylinder engines on Volkswagen Golf SportWagen?

  A:

  When the battery is removed, a number of systems will have to be re-learned until they will work correctly. The first step is to relieve the fuel system pressure and then release the battery and the battery tray. Lift the front of the vehicle and lift the vehicle safely on jackstands, blocking the wheels at the other end. Take out splash shield on the underside, engine cover, and air filter housing. The next step is to remove the alternator, ignition coils and power steering pump, drain the cooling system and take out the coolant expansion tank. Next, dismantle the Valve Cover and intake manifold, then the accessories support bracket bolts and bracket, and put the support strap back in place to help in the process of the cylinder head removal. Take the Camshaft cover off, breadthwise lock the camshafts and disconnect the camshaft sprocket so that the Timing Chain can be out of the way. Unplug the exhaust pipe, the electrical connections of the oxygen sensor, and harness holders. Unscrew the cylinder head bolts in the same order in which they were installed with the exception that the bolt nearest to the tool holding the instrument, cannot be removed, then loosen the tool and slide to the side of the tool to reach the bolt. Inspection: To be inspected, the mating faces of the cylinder head and block should be clean, using a gasket remover and scraper, being careful not to damage the alloy of aluminum. Eliminate carbon deposition around the oil and water outlets, and inspect the surfaces involved in the mating process as a precision straightedge and feeler gauge. In case any surface goes above the limit of warpage, refer to an automotive machine shop. To install, clean the mating surfaces and install the alignment dowels. It is important to make sure that the holes of the cylinder head bolts are not filled with oil or coolant to prevent hydraulic lock. Add a bead of RTV sealant to the area of timing chain of the cylinder block and place a new gasket to the block surface with the mark TOP facing upward. Apply one more bead RTV sealant to the top of the head gasket, and place the cylinder head inside into position within five minutes using an assistant to help. Apply engine oil to the new cylinder bolt threads and install the bolts with your fingers and hand-tighten them in the given order to the first torque value and then repeat the process by one more step using the angle torque technique. Let the engine rest after 30 minutes without turning the crankshaft. Install the accessories bracket and bolts as they come in that order tightening them to the given torque. Tilt the valve timing and pull off the camshaft holding tool and crankshaft locking pin. Turn the crankshaft over at least two full rotations before engaging the engine, and observe resistance. In case any is experienced, then pause and enquire about the matter. Last but not least, fit the rest of the items taken off and replace engine oil and filter, and fill up the cooling system.