Genuine Volkswagen Passat Cylinder Head

Volkswagen Passat Cylinder Head Parts and Q&A

• Cylinder Head
  03G-103-351-C
  Q: What steps should be followed to perform a cylinder head removal and installation procedure on Volkswagen Passat?

  A:

  This procedure can cause a trouble code to be set, and some visits to a dealer service department or a repair shop with a scan tool that is compatible with the scan tool and with the proper scan tool a visit is required to adjust the cam sensor(s) and clear the code. It is important to check that the engine is thoroughly cold before turning it. Exhaust Manifold can be attached to the cylinder head which can be taken off. Start with removing the cable to the negative battery terminal, and have the anti-theft radio activation code, because disconnection of battery can cause driveability problems and warning lights which will not be solved without a scan tool. Empty the engine coolant, unscrew the front exhaust pipe and the valve cover(s) and Intake Manifold, and the power steering hose in case the right cylinder head is to be removed. Take out the Timing Belt and covers on the rear of the timing belts, and on SOHC engines, the coolant pipe at the rear of the cylinder heads and in DOHC engines, the secondary air injection pipes and coolant pipes. Disconnect all electrical connections and coolant hose and label them to be replaced. Relax the cylinder head bolts gradually until they can be removed by hand and old bolts are thrown away. Ensure that nothing is attached to the cylinder head, next make sure that it is not attached to the cylinder block and then lift it off, with the help of another person in case it is heavy. Take out the gasket on the top side of the block to identify it. Should there be a need to open the cylinder head to service it, it is important to disassemble the exhaust manifold and proceed to service the required part and ensure that the exhaust manifold is returned to location before the cylinder head is reattached to the vehicle. Clean oil and water passages Cylinder block/Clean mating faces of the cylinder head and block off completely, wiping off all gasket and carbon and making sure that no debris gets into the oil and water passages. Examine the mating surfaces, and look to see whether they are warped, and in that case a straight-edge may be used. Wipe the cylinder head bolt holes using an appropriate tap making sure that they are dry. To avoid damaging the piston during re-cylinder head installation, set the crankshaft to a non-TDC position. The valve seats must be adjusted in case the head has been resurfaced. Install the new head gasket on the cylinder block, making sure that it fits well, and then install the cylinder head over the block, making certain that the gasket is well seated. Install new cylinder head bolts manually, then screw them in a sequence with the required torque and angle of rotation, precision is required with an angle-measuring gauge. To install the timing belt, first position the mark on the pulley to correspond with the front cover then fit the timing belt tensioner and camshaft sprockets (where removed) and then fit the timing belt. Install everything in the order of removal and then refill the engine oil, the coolant and test the engine to ascertain whether it is leaking or not.
• Cylinder Head
  06A-103-351-L
  Q: What steps should be taken for thorough cleaning and inspection of the cylinder head and valve train components during an engine overhaul on Volkswagen Passat?

  A:

  A careful cleaning of the cylinder head and the associated valve train components after which a careful inspection of the same will help you decide the type of valve service work required during the engine overhaul. Start by removing all the old gasket material and sealant off the mating surfaces of the head gasket, intake manifold and exhaust manifold, being careful not to gouge the cylinder head. Clean the crest formed on the coolant passages and wipe off the deposits on the different holes with a hard wire brush. Place a fitting-size tap in each of the threaded holes to remove corrosion and thread sealant, and clear the debris with compressed air. Cleaning the threads of the exhaust and intake manifold studs with a wire brush and clean the cylinder head with solvent and dry thoroughly with the help of compressed air to hasten the process. Chemicals can also be decarbonized which can prove useful in cleaning although careful use is important. Clean individual valve springs, keepers and retainers to prevent mixing of parts and also scrape off thick deposits on the valves and then thoroughly clean with motorized wire brush. Check head, coolant leak, and other damages, refer to automotive machine shop. Inspect the head gasket mating surface with a straightedge and a feeler gauge to determine warpage and inspect the valve seats to determine pitting, cracking or burning. Determine the clearance of the valve stem-to-guide using a dial indicator and in case of any doubts regarding the valve guides, a machine shop must check. Check the wear, deformation, and cracks of each face of valves and check the size of the stem in multiple points to make sure that it is not too large. Test the wear of each of the valve springs and check the free length of each, replacing any shortened springs. Straighten all springs and examine wear and cracks of retainers, wear and cracks of seats and keepers and replace any doubtful parts. Check the journals of the camshaft bearers on the cylinder head and submit them to a machine shop to have the valves serviced where the journals are gouged or scored, which means that the head must be replaced. In case the inspection indicates that the valve parts are not in good conditions and are worn to a point that exceeded the required limits, then, assemble the valves in the cylinder head.