Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 665
– Loosen the hose clamp -2-.
– Free up the coolant hose -3-.
– Remove the bolts -arrows-.
– Disconnect the connector -1- from the Charge Air Pressure
Sensor - G31- , and remove the right air guide pipe.
– Loosen the clamps -arrows- and remove the coolant hoses.
– Swing the coolant line -1- to the side.
– Disconnect the connectors:
1 - For Oil Pressure Switch - F22-
2 - For Reduced Oil Pressure Switch - F378-
5 - For Piston Cooling Nozzle Control Valve - N522-
– Remove the bolts -arrows-.
– Remove the bolt -1- and the nut -3- and then remove the
bracket -2- for the intake manifold.
– Disconnect the connectors:
1 - For Throttle Valve Control Module - GX3-
2 - For Intake Manifold Sensor - GX9-
3 - For Fuel Pressure Sensor - G247-
– Remove the connector -4- from the bracket.
– Free up the wiring harness and push it to the side.
– Free up the wiring harness -1 and 2- from the air guide pipe.
– Loosen the screw-type clamp -3-.
– Remove the bolts -arrows-.
– Loosen the hose clamp -arrow- and remove the charge air
hose -1- with the air guide pipe downward.
– Disconnect the connector -3- for Knock Sensor 1 - G61- from
the bracket.
– Disconnect the connectors -2 through 4-.
– Disconnect the connectors and free up the wires.
1 - For Intake Manifold Runner Control Valve - N316-
2 - For Coolant Shut-Off Valve - N82-
3 - For Engine Coolant Temperature Sensor - G62-
4 - For Oil Pressure Switch, Level 3 - F447-
– Remove the bolts -arrows-.
– Remove the bolts -arrows- and nut -1-.
– Remove the heat shield -2-.
– Remove the bolt -1-. Just loosen bolt -3-.
– Remove the turbocharger bracket -2-.
– Remove the nuts -arrows-.
– Remove the turbocharger from the cylinder head and tie up
behind.
– Remove the bolts -arrows-.
– Remove the cylinder head bolts in the sequence -1 to 10-.
Note
Make sure all wires and cables are disconnected.
– Remove the cylinder head and place it on a soft surface
(foam).
Installing
Note
♦
Replace the bolts that were tightened with an additional turn.
♦
Replace the gaskets, seals and self-locking nuts.
♦
The hose supports, air guide pipes and hoses must be free of
oil and grease before installing.
♦
Secure hose connections with standard production clamps.
Refer to the Parts Catalog.
♦
The screws on the used clamps must be sprayed with a rust
remover before installing.
– Only unpack new cylinder head gasket immediately prior to
installation. The silicon layer and the cylinder head seal re‐
cessed area must not be damaged.
– Carefully remove sealant residue from cylinder head and cyl‐
inder block. Make sure that no long scrapes or scratches
result. Carefully remove all grinding and sanding residue.
– Clean the cylinder head bolt blind holes. If necessary with
compressed air.
– Set cylinder head gasket in place.
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