[Cody britt]

Hey guys I bought a jetta with 160,000 miles on the clock for 600 bucks. It has a popped timing belt. I bought the Bentley book thinking that it would have instructions to remove the head. I have the head bolts out cam gear and basically everything on the front of the head, I removed the egr and exhaust downpipe from turbo. But I don’t really know how to remove the intake and exhaust to remove head. Thank you for any help.

 

[Keithuk]

First posts normally go in introductions else you could get a free fix and we never see you again!!!

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Any problems search TDI Wiki as that covers write ups and forum posts.

 

[terpsgeorgia]

Hey Cody.

I don't think there is a wiki but have you looked at this manual?

(http://mrtn.m4ti.net/mk5/Jetta & Golf Variant/Workshop Manuals/Drive Unit/4-cylinder diesel engine with unit injector.pdf).

To give you an idea of layout, look at the gaskets. I don't recall there being any "magic", just patience and care accessing some of the hidden ones.
Intake:
https://www.idparts.com/intake-manifold-cleaning-kit-a5-brm-p-4460.html
Exhaust:
https://www.idparts.com/exhaust-manifold-gasket-brm-p-1829.html
IIRC, the torque on both intake and exhaust is 18 ftlbs?

You will need to replace a bucket-load of TTY bolts. There is a kit with all the gaskets and bolts required, last time I looked, it was like $150 which includes all the bolts, gaskets, o-rings etc. Google should find it. Make sure you have access to the cam and crank lock tools to re-install the timing belt (when you get there). If you don't, I have them and am about an hour North of Atlanta (depending on where you are in Atlanta).

 

[OVofNM]

Hi Cody. I did not see a HowTo for removal of intake/exhaust manifolds for a BRM. I have a 2006 Jetta BRM (manual transmission) engine project coming up, so I'll do my best to take some good pictures. It would be useful if you could do the same - we can compare notes... Maybe we can develop a step-by-step procedure.

Here are some pictures I found: thank you e-Bay and google search!