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.