Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Engine Sling (2024 A)
• Engine Support (T10014)
• Assembly Tool (T10352)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Ignition Coil Puller (T40039)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Shop Crane (VAS 6100)
• Engine Bung Set (VAS 6122)
• Drip Tray for VAS 6100 (VAS 6208)
• Polydrive Bit and Drive Socket (T10070)
Removing
• During installation, cable ties must be installed in the same location.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the electrical connector - arrow - and free up the electrical wire.
Risk of scalding due to hot steam and hot coolant.
The coolant system is under pressure when the engine is warm.
Reduce pressure by covering the coolant expansion tank cap with a cloth and open carefully.
- Open the coolant expansion tank cap.
- Remove the front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converters ] Front Exhaust Pipe with Catalytic Converters.
- Remove the right front wheel.
- Remove the noise insulation.
- Remove the right front wheel housing liner.
- Loosen the clamps - items 1 and 2 - and remove the charge air hose.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
- Remove the bolt - 1 - and remove the charge air pipe downward.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the charge air pipe.
- Disconnect the connectors - 1 and 2 - and free up the wire - arrows -.
Vehicles with All Wheel Drive (AWD):
- Remove the right drive axle heat shield bolts - 1 - using the hex ball socket (3247) and remove the shield - A -.
Continuation for all Vehicles:
- Remove the bolts - 1 and 2 - and remove the turbocharger support.
- Remove the banjo bolt - 2 - and move the coolant line to the side.
Vehicles with Front Wheel Drive (FWD):
- Remove the bolts - 1 - for the oil return line.
Vehicles with AWD:
- Remove the oil return line bolts from the crankcase.
Continuation for all Vehicles:
- Remove the bolt - 3 - for the oil supply line.
- On vehicles with a noise generator: Remove the charge air pipe leading to the noise generator.
- Disconnect the connector from the camshaft adjustment valve 1 (N205) - 1 -.
- Disconnect the connectors from the ignition coils and free up the wiring harness.
- Remove the ignition coils using the ignition coil puller (T40039).
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the bolts - arrows -.
- Remove the charge air pipe bolt - arrow -.
- Loosen the hose clamp - 2 - and remove the charge air pipe together with the crankcase ventilation.
The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.
- Disconnect the lines - 1 through 3 - from the fuel transfer.
1) Vent line
2) Vacuum line
3) Fuel supply line
- Disconnect the coolant line - arrow - from to the coolant expansion tank.
- Remove the coolant hoses - arrows - from the coolant pipe.
- Disconnect the ground wire (GND) - 3 - and remove the bolt - 4 -.
- Disconnect the vacuum hoses - arrows -.
- Loosen the bolts - 1 though 4 - and remove the heat shield together with the coolant pipe.
- Disconnect the oil supply line from the turbocharger - 4 -.
• Remove the bolt - 2 - from the heat shield using a 6 mm - A - hex socket. The hex socket must be at least 5 cm - B - long. A socket that tapers to 6 mm at the tip is too wide.
- Disconnect the electrical connector - 2 - from the fuel pressure regulator valve (N276).
Engine Code CBFA:
- Disconnect the connector - A - and hose - B - from the secondary air injection solenoid valve (N112).
- Loosen the coolant pipe; remove the bolts - arrows -.
Continuation for all Vehicles:
- Disconnect the coolant hose from the side connection on the cylinder head.
- Disconnect the electrical connectors - 1 through 4 -.
- Free up the wire - 5 -.
- Disconnect the vacuum hose - 6 - leading to the Evaporative Emission (EVAP) canister.
GTI:
- Disconnect the vent line - 1 -, unlock the EVAP canister - A - and remove it - B -.
Continuation for all Vehicles:
- Disconnect the electrical connectors - 1 - and pull the connectors out of the retainer.
- Disconnect the electrical connectors - 2 through 4 -.
- Disconnect the coolant line from the intake manifold, when doing this, remove the bolts - arrows -.
- Remove the intake manifold bracket by removing the nut - 1 - and bolt - 2 -.
- Remove the oil filter.
- Disconnect the coolant hoses - arrows - and move them to the side.
- Remove the bolts - arrows - and then the camshaft adjustment valve 1.
- Remove the upper timing chain cover. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.
The control valve has left hand threads.
- Remove the control valve in the - direction of the arrow - using the assembly tool (T10352).
- Remove the bolts - arrows - and remove the bearing bracket.
- Rotate the vibration damper into the Top Dead Center (TDC) position - arrow - using the counter hold tool (T10355).
• The notch on the vibration damper must line up with the arrow mark - arrow - on the lower timing chain cover.
• The marks - 1 - on the camshafts must point upward.
- Carefully mark the position of the drive chain to the sprockets - A arrows - with a waterproof marker. Also mark the position of the drive chain to the guide rail - B arrows -. These marks are necessary for reinstallation.
- Remove the plug - arrow -.
The locking wedge in the chain tensioner must be lifted in order to release the tension from the chain tensioner. Sand the end of the locking pin (T40011) down to a point. A screwdriver with a head approximately 1.5 mm wide can also be used.
There is a risk of damaging the chain tensioner. Proceed very carefully.
- Insert a screwdriver in the hole on the chain tensioner in the - direction of arrow 1 - and lift the locking wedge in the chain tensioner.
- In order to tension the chain tensioner, rotate the crankshaft opposite the engine rotation direction in the - direction of arrow 2 - and secure it using a locking pin (T40011).
• The intake camshaft switches in the engine rotation direction.
- Remove the guide pin - 1 - and guide the tensioning rail - 2 - downward.
- Remove the upper guide rail - 3 - by unlocking the latch located in the center with a screwdriver and pushing the guide rail forward.
- Remove the camshaft timing chain from the sprockets.
Danger of damaging the valves, piston head and lower timing chain cover.
• If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turned further.
• Panels are installed on the lower timing chain cover to prevent the chain from falling down. The panels can bend if the crankshaft is rotated when the chain is loose.
- Turn the sealing plugs - arrows - counterclockwise 90° in the - direction of the arrow - and remove them.
- Remove the ball studs - 1 and 2 -
- Remove the cap.
- Remove the bolts - arrows -.
- Remove the cylinder head bolts in sequence - 1 through 5 - using the polydrive bit and drive socket (T10070) until 2 are left.
• To remove the cylinder head bolts, rotate the camshaft with a wrench if necessary.
• Make sure all wires and cables are disconnected!
• Pay attention to the tension and guide rails when lifting the cylinder head.
- Install the engine support (T10014) with each of the two small and large washers as illustrated.
- 1 - M8 washer, small.
- 2 - M8 washer, large. The outer diameter of the washer must be larger than the hole in the bracket.
- 3 - M8 x 30 bolt.
- Install the engine sling (2024 A) to the engine support (T10014) and to the left front lifting eye on the cylinder head.
- Secure the engine sling (2024 A) with the workshop crane and gently lift the cylinder head.
- Remove the last two cylinder head bolts.
• Carefully lift the cylinder head until the guide rail for the camshaft timing chain is free.
• The tension and guide rails must not be damaged.
- Lay the cylinder head on a soft surface, such as foam.
Installing
• Tightening specifications, refer to => [ Cylinder Head Overview ] Cylinder Head Overview.
The sealing surfaces could be damaged.
• Carefully remove the sealant from the cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging the cylinder block.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Risk of cylinder head gasket leaking.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder head is installed, only remove the plastic base right before the cylinder head is installed to protect open valves.
Risk of damaging valves and piston heads after working on the valvetrain.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace the bolts which have been tightened to a torque angle.
• Replace O-rings, seals and self-locking nuts.
• Note the different sealant for the cylinder head sealing surfaces and bolts.
• Secure all hose connections with hose clamps appropriate for the model.
• When installing a replacement cylinder head, rotate the camshaft to TDC and mark the new sprockets exactly the same as on the old sprockets (note the factory colored mark on the sprockets).
• When installing a replacement cylinder head, all of the contact surfaces between the supports, roller rocker arms and cam running surfaces on the camshaft must be lubricated before installing the cylinder head cover.
• The engine oil and coolant must be changed if the cylinder head or cylinder head gasket are replaced.
- Support the cylinder head with the workshop crane and position it above the cylinder block.
• Carefully lower the cylinder head.
• The tension and guide rails must not be damaged.
• Pay attention to the alignment pins - arrows - in the cylinder block.
• Observe the cylinder head gasket location, identification: The part number must be visible from the intake side.
When rotating the crankshaft, make sure the timing chain cannot damage any other components.
- In the event the crankshaft has been rotated in the meantime: Set the piston for cylinder 1 to TDC and rotate the crankshaft back again slightly.
- Set the cylinder head in place.
- Install the cylinder head bolts and tighten them by hand.
• In order to be able to turn the cylinder head bolts, the intake camshaft must be turned with a wrench.
• There is no requirement to tighten the cylinder head bolts after repairs.
- Cylinder head bolt tightening sequence, refer to => [ Cylinder Head Bolt Tightening Sequence ] Cylinder Head Overview.
When rotating the crankshaft, make sure the timing chain cannot damage any other components.
- Rotate the vibration damper to the TDC position - arrow - using the counter hold tool (T10355).
• The notch on the vibration damper must line up with the arrow mark - arrow - on the lower timing chain cover.
- Mount the timing chain on the intake camshaft. The marks must align.
- Turn the intake camshaft in the - direction of the arrow - with a wrench until the timing chain is taut. Hold the intake camshaft secure in this position.
- Mount the timing chain on the exhaust camshaft: the marks on the drive chain and sprockets - arrows A - and the drive chain and guide rail - arrows B - must align.
- Install the upper guide rail - 3 -.
- Move the tensioning rail - 2 - up and tighten the guide pin - 1 -.
• If the marks on the drive chain and guide rail - B arrows - do not align even though the engine is at TDC, the drive chain has skipped on the crankshaft sprocket. Check the valve timing. Refer to => [ Valve Timing, Checking ] Adjustments. If the timing does not agree, the camshaft timing chain must be positioned again. Refer to => [ Camshaft Timing Chain ] Camshaft Timing Chain.
The rest of the installation is performed in reverse order of removal, noting the following:
- Change the engine oil
- Replace the coolant. Refer to => [ Draining and Filling ] Procedures.