Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Assembly Tool (T10352)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Lever (T40243)
• Locking Tool (T40267)
• Camshaft Locator (T40271)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Engine Bung Set (VAS 6122)
• Drip Tray for VAS 6100 (VAS 6208)
• Polydrive Bit and Drive Socket (T10070)
• Engine Sling (2024 A)
• Engine Support (T10014)
• Ignition Coil Puller (T40039)
Removing
• During installation, cable ties must be installed at 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 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 one of the following:
GTI and Eos, refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
Passat and CC, refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
Tiguan, refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the right front wheel.
- Remove the noise insulation. Refer to one of the following:
GTI and Tiguan
Eos and Passat
CC,
- Remove the front right wheel housing liner..
- Loosen the charge air hose clamps - 1 and 2 - and remove the charge air hose.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.
- Remove the bolt - 1 - and remove the charge air pipe downward.
- Remove the charge air pipe 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 -.
with All Wheel Drive (AWD)
- Remove the right drive axle heat shield - A - bolts - 1 - using the hex ball socket (3247).
Continuation for All
- Remove the bolts - 1 and 2 - and remove the turbocharger support.
- Remove the banjo bolt - 2 - and move the coolant line to the side.
with Front Wheel Drive (FWD)
- Remove the bolts - 1 - for the oil return line.
with AWD
- Remove the oil return line bolts at the crankcase.
Continuation for All
- Remove the bolt - 3 - for the oil supply line.
- Only vehicles with a noise generator, remove the charge air pipe from the noise generator.
- Disconnect the connector from the camshaft adjustment valve 1 (- 1 -).
- Disconnect the connectors from the ignition coils and free up the wiring harness.
- Remove the ignition coils using the ignition coil puller (T40039).
- Remove the crankcase ventilation bolts - arrows -.
- Disconnect the hose for the crankcase ventilation - 1 -.
- 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 eye wear 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 - at the bracket.
1 - Vent line
2 - Vacuum line
3 - Fuel supply line
- Disconnect the coolant line - arrow - from the expansion tank.
- Remove the coolant hoses - arrows - from the coolant pipe.
- Remove the nut - 3 - and ground wire (GND), 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.
- Remove the banjo bolt and the oil supply line - 4 - from the turbocharger.
• Remove the bolt - 2 - from the heat shield using a 6 mm - A - hex socket. The hex socket must be at least 5 cm long - B -. A socket that tapers to 6 mm at the tip is too wide.
- Disconnect the connector - 2 - from the fuel pressure regulator valve.
Engine Code CBFA
- Disconnect the connector - A - and hose - B - from the secondary air injection solenoid valve.
- Loosen the coolant pipe, remove the bolts - arrows -.
Continuation for All
- Disconnect the coolant hose from the connection on the cylinder head.
- Disconnect the connectors - 1 through 4 -.
- Free up the wire - 5 -.
- Disconnect the vacuum hose - 6 - leading to the Evaporative Emission (EVAP) filter.
GTI
- Disconnect the vent line - 1 -, unlock the EVAP canister - A - and remove it - B -.
Continuation for All
- Disconnect the connector - 1 - and pull the connector out of the retainer.
- Disconnect the 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 a 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 using the counter hold tool (T10355) into the Top Dead Center (TDC) position - arrow -.
• The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.
• The marks - 1 - on the camshafts must point upward.
- Apply marks on the camshaft timing chain and the cylinder head - arrows - to match the marks on the sprockets - 1 - using a waterproof marker.
- In addition, apply marks on the camshaft timing chain to the camshaft timing chain guide rail - 2 - with a waterproof marker.
- Remove the plug - arrow -.
- Remove the bolts - arrows -.
- Remove the bolt - arrow -.
Two different chain tensioners may be installed.
Version 1:
- Install the lever (T40243) - arrows -.
- Lift up the locking wedge for the chain tensioner - arrow 1 -. 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.
- Slowly press and hold the lever (T40243) in the - direction of arrow 2 -.
- Secure the chain tensioner using the locking pin (T40011).
Version 2:
- Install the lever (T40243) - arrows -.
- Press the chain tensioner lock ring - arrow - together and slowly press and hold the lever (T40243) in the - direction of the arrow -.
- Secure the chain tensioner using the locking tool (T40267).
Continuation for All
- Remove the lever (T40243).
- Bolt the camshaft locating tool (T40271/2) to the cylinder head and push the tool into the sprocket splines in the - direction of arrow 2 -. If necessary, rotate the intake camshaft in the - direction of arrow 1 - using a wrench.
- Bolt the camshaft locating tool (T40271/1) to the cylinder head. Counter hold the camshaft with a wrench in a clockwise direction - arrow -.
- Remove the guide pin - A - and remove the tensioning rail while continuing to counter hold the camshaft.
- Rotate the exhaust camshaft further in a clockwise direction - 1 - until the camshaft locating tool (T40271/1) can be pushed into the sprocket splines in the - direction of arrow 2 -.
- Remove the guide rail - 1 - by unlatching the latch with a screwdriver and pushing the guide rail forward. Mark the position of the sprockets - arrow - to the camshaft locating tools.
- Remove the camshaft timing chain from the sprockets.
Risk of damaging valves and piston crowns.
• If the camshaft timing chain was removed from the cylinder head, then the crankshaft must not be turned further.
- Turn the plugs - arrows - counterclockwise 90° (1/4 turn) in the - direction of the arrow - and remove them.
- Remove the ball studs - 1 through 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).
• Make sure all wires and lines are disconnect!
• Pay attention to the tensioning and guide rails when lifting the cylinder head.
- Remove the cylinder head.
- Lay the cylinder head on a soft surface, such as foam.
Install the cylinder head.
If the camshafts are replaced, the previous marks must be transferred. For this reason, the following steps are important:
- Mark the camshaft sprockets to the camshaft locating tools (T40271/1) and (T40271/2) - arrow - on the removed cylinder head.
• The following distance gauge indicates whether the marks were transferred correctly later on.
- Measure the distance from the left outer edge of the bar - A - to the mark - B - on the intake camshaft sprocket and write down the value.
- Measure the distance between the mark on the intake camshaft sprocket - B - and the mark on the exhaust camshaft sprocket - C - and write down the value.
- Rotate the intake camshaft using a wrench in the - direction of arrow 1 -, slide the camshaft locating tool (T40271/2) out of the sprocket splines in the - direction of arrow 2 - and bring the camshaft into the rest position.
- Remove the camshaft locating tool (T40271/2).
- Rotate the exhaust camshaft using a wrench in the - direction of arrow 1 -, push the camshaft locating tool (T40271/1) out of the sprocket splines in the - direction of arrow 2 - and bring the camshaft into the rest position.
- Remove the camshaft locating tool (T40271/1).
Now install the cylinder head and transfer the marks that were made when it was removed.
- Bolt the camshaft locating tool (T40271/2) to the installed cylinder head.
- Rotate the intake camshaft in the - direction of arrow 1 - until the mark - 3 - on the sprocket aligns with the camshaft locating tool (T40271/2).
- Push the camshaft locating tool (T40271/2) into the sprocket splines in the - direction of arrow 2 -.
- Compare the distance from the left outer edge of the bar - A - to the mark - B - with the previously noted value.
- Bolt the camshaft locating tool (T40271/1) to the cylinder head.
- Rotate the exhaust camshaft in the - direction of arrow 1 - until the mark - 3 - on the sprocket aligns with the camshaft locating tool (T40271/1).
- Push the camshaft locating tool (T40271/1) out of the sprocket splines in the - direction of arrow 2 -.
- Compare the distance between the mark on the intake camshaft - B - to the mark on the exhaust camshaft - C - with the previously noted value.
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 the new cylinder head gasket immediately prior to installation.
• To prevent the cylinder head gasket silicone layer and recessed areas from being damaged, always handle the gasket extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder is installed, only remove the plastic base right before the cylinder head is installed to protect the open valves.
Risk of damaging valves and piston heads after working on the valvetrain.
• To ensure the valves do not strike the pistons when starting, carefully rotate the engine at least 2 full revolutions.
• Replace the bolts which have been tightened to an additional torque angle.
• Replace self-locking nuts, sealing rings, seals and O-rings.
• If a replacement cylinder is installed, the contact surfaces between the hydraulic lash adjusters, roller rocker arms and cam running surfaces must be lubricated before installing the camshafts.
• The hose supports, charge air pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Parts Catalog.
• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.
- Set the cylinder head gasket in place.
• Pay attention to centering pins - arrows - in cylinder block.
• Observe he cylinder head gasket location, identification: The part number must be visible from the intake side.
By rotating the crankshaft, the timing chain tightens upward so that it does not jam.
- In the event the crankshaft has been rotated in the meantime: Set the cylinder 1 piston to TDC and rotate crankshaft back again slightly.
- Set the cylinder head in place.
- Install the cylinder head bolts and tighten them hand tight.
- Cylinder head bolt tightening sequence, refer to => [ Cylinder Head Bolt Tightening Sequence ] Cylinder Head Overview.
• There is no requirement to retighten the cylinder head bolts after repairs.
By rotating the crankshaft, the timing chain tightens upward so that it does not jam.
- Rotate the vibration damper using the counter hold tool (T10355) into the TDC position - arrow -.
• The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.
- Position the marks on the chain links - arrows - at the sprockets - 1 - to install the camshaft timing chain.
- Install the upper guide rail - 2 -.
• Use the help of a second mechanic to hold the exhaust camshaft in place.
- Slowly rotate the exhaust camshaft in the - direction of arrow 1 - until the camshaft locating tool (T40271/1) can be pushed out from the sprocket splines in the - direction of arrow 2 -.
- Carefully release the camshaft, until the camshaft timing chain is laying on the upper guide rail. Hold the camshaft in this position.
- Continue to hold the camshaft and install the camshaft timing chain tensioning rail. Install and tighten the guide pin - A -.
- Remove the camshaft locating tool (T40271/1).
- Slide the camshaft locating tool (T40271/2) out of the sprocket splines in the - direction of arrow 2 -. If necessary, slightly rotate the intake camshaft in the - direction of arrow 1 - using a wrench.
- Remove the camshaft locating tool (T40271/2).
- Check the valve timing. The camshaft timing chain and cylinder head - arrows - must align with the marks on the sprockets - 1 -.
- The marks on the camshaft timing chain and the camshaft timing chain guide rail - 2 - must align with one another.
- The notch on the vibration damper must be opposite the mark on the lower timing chain cover - 3 -.
• If the self-made marks are no longer visible, check the valve timing, refer to => [ Valve Timing, Checking ] Adjustments.
- Install the bearing bracket evenly. Do not tilt it and install the bolts - arrows - hand tight.
- Remove the locking pin (T40011) or the locking tool (T40267) , depending on the version.
- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Install the bolt - arrow -.
- Install the control valve, see - item 6 - in the => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Rotate the intake camshaft using a wrench and mount the timing chain.
Further installation is in the reverse order of removal. Note the following:
- Change the engine oil.
- Replace the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.