Cylinder Head, Removing and Installing
Cylinder Head, Removing and Installing
Special tools, testers and auxiliary items required
• Lifting tackle (2024 A)
• Bracket (T10014)
• Assembly Tool 10352 (T10352)
• Counter-holder tool (T10355)
• Securing pin (T40011)
• Puller (T40039)
Special tools, testers and auxiliary items required
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Shop crane (VAS 6100)
• Engine bung set (VAS 6122)
• Drip tray for workshop crane (VAS 6208)
• Polydrive bit and drive socket (T10070)
Removing
• During installation, cable ties must be re-installed at the same location.
- Remove the engine cover => [ Engine Cover, Removing and Installing ] Engine Cover, Removing and Installing.
- Remove the air filter => [ Air Filter, Removing and Installing ] Air Filter, Removing and Installing.
- Loosen the hose clamp - 2 -.
- Remove bolt - 4 -.
- Disconnect the electrical connectors - arrow - and free up the electrical wire.
CAUTION!
Risk of scalding due to hot steam and hot coolant.
When the engine is warm the cooling system is under pressure.
Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.
- Open coolant reservoir cap.
- Remove front exhaust pipe with catalytic converter => [ Catalytic Converters with Front Exhaust Pipe, Removing and Installing ] Service and Repair.
- Remove the right front wheel.
- Remove the noise insulation
- Remove the front right wheel housing liner => Body
Exterior 66 Wheel Housing liner.
- Remove the air guide pipe - items 1 and 2 -.
- Drain coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Remove the bolt - 1 - and remove the air guide pipe downward.
- Remove bolts - arrows -.
- Remove the air guide pipe by lifting the clamps - items 1 and 2 -.
- Disconnect electrical connectors - 1 and 2 - and free up electrical wire - arrows -.
Vehicles with auxiliary heater:
- Remove the bolts - 1 and 2 - and swivel the coolant tubs to the left.
Vehicles with all wheel drive:
- Remove the right axle shaft heat shield - A - bolts - 1 - using Socket AF 8 (3247).
All:
- Remove 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:
- Remove the bolts - 1 - on the oil return line.
Vehicles with all wheel drive:
- Remove the oil return line bolts on the crankcase.
All vehicles:
- Remove the bolt - 3 - on the oil supply line.
Rabbit and Scirocco:
- Remove the charge air guide leading to the noise generator.
All:
- Disconnect the connector from the Camshaft Adjustment Valve 1 (N205) - 1 -.
- Disconnect the electrical connectors on the ignition coils and free up the wiring harness.
- Remove the ignition coils with the puller (T40039).
Engine codes BZB, CAWA, CAWB and CGYA:
- Press the release buttons, remove the air guide hose - 1 - and move them to the side.
- Remove the air guide pipe bolt - arrow -.
- Remove the air guide pipe; to do this, loosen the hose clamp - 2 -.
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the bolts - arrows - and remove the crankcase ventilation.
Engine codes CBFA, CCTA and CCTB:
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the bolts - arrows -.
- Remove the air guide pipe bolt - arrow -.
- Loosen the hose clamp - 2 - and remove the air guide pipe together with the crankcase ventilation.
All:
CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Disconnect the wires - 1 to 3 - from the fuel transfer.
1) Vent line
2) vacuum line (only CBFA, CCTA and CCTB)
3) Fuel supply line
- Disconnect the coolant line to the coolant reservoir - arrow -.
- 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 -.
• On 2.0L engines, remove the bolt - 2 - from the heat shield using a 6 mm - A - hex multi-point socket. The hex socket must be at least 5 cm - B - long. A socket that is 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 (AIR) Solenoid Valve (N112).
- Loosen the coolant pipe; remove the bolts - arrows -.
All:
- Disconnect the coolant hose from the side connection on the cylinder head.
- Disconnect the electrical connectors - 1 through 4 -.
- Free up the electrical cable - 5 -.
- Disconnect the vacuum hose - 6 - leading to the EVAP filter.
Rabbit and Scirocco:
- Disconnect the vent line - 1 -, unlock the EVAP cannister - A - and remove it upward - B -.
All:
- 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 mounting 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 remove Camshaft Adjustment Valve 1 (N205)
- Remove timing chain upper cover => [ Upper Timing Chain Cover, Removing and Installing ] Upper Timing Chain Cover, Removing and Installing.
CAUTION!
The control valve has a left thread.
- Remove the control valve using Assembly Tool 10352 (T10352) in the - direction of arrow -.
- Remove the bolts - arrows - and remove the bearing bracket.
- Rotate the vibration damper using the Counter Hold Tool (T10355) into the "OT" position - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
- Carefully mark the drive chain/chain sprockets - arrows - with a waterproof marker. These marks are necessary for reinstallation.
- Remove the plug - arrow -.
- Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner - arrow direction 1 -.
- In order to tension the chain tensioner, turn the crankshaft opposite the direction of the engine rotation - arrow direction 2 - and secure it using Securing Pin (T40011).
• The intake camshaft switches in the engine direction of rotation.
- Remove the bolt - 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.
• When the lower timing chain cover is installed, the loose chain on the crankshaft can not jump off.
- Remove camshaft timing chain from chain sprockets.
CAUTION!
Danger of damaging the valves, piston head and lower timing chain cover.
• If the camshaft timing chain was removed form the cylinder head, then the crankshaft may not be turn 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 plug - arrows - counterclockwise 90° in the - direction of the arrow - and remove it.
- Remove the ball head - 1 through 2 -
- Remove the oil filler cap.
- Remove the bolts - arrows -
- Remove the cylinder head bolts in sequence - 1 through 5 - using Polydrive bit and drive socket (T10070) until 2 are left.
• To remove the cylinder head bolts, turn the camshaft with a wrench if necessary.
• Make sure all wires and cables are disconnect!
• Pay attention the tension and guide rails when lifting the cylinder head.
- Install the Engine Support (T10014) each each of the two small and large washers, as shown in the illustration.
- 1 - washer, M8, small.
- 2 - washer, M8, large. The outer diameter of the washer must be larger than the hole in the bracket.
- 3 - bolt M8 x 30.
- Connect the Engine Sling (2024 A) in the Engine Support (T10014) and in the front left lifting eye on the cylinder head.
- Mount the Engine Sling (2024 A) into the workshop crane and gently lift the cylinder head.
- Remove the last two cylinder head bolts.
CAUTION!
• Carefully lift the cylinder head until the guide rail for the camshaft timing chain is free.
• The tension- and guide rail must not be damaged.
- Lay the cylinder head on a soft surface, such as foam.
Installing
• Tightening specifications => [ Cylinder Head, Assembly Overview ] Cylinder Head, Assembly Overview.
CAUTION!
The sealing surfaces could be damaged.
• Carefully remove sealant residue from cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging 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 seal leaking.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.
Risk of damaging valves and piston heads after working on valvetrain.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace bolts which have been tightened to torque.
• Replace sealing rings, seals and self-locking nuts.
• Note different sealant for cylinder head sealing surfaces and bolts.
• Secure all hose connections with hose clamps appropriate for the model.
• When installing a replacement cylinder head, turn the camshaft to OT and mark the new chain sprockets exactly the same as on the old chain sprockets -arrows- (note the factory color marking on the chain sprockets).
• If an exchange cylinder head is installed, all contact surfaces between bearing elements, roller rocker levers and cam running surfaces of camshafts must be oiled before installing cylinder head cover.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.
- Hang the cylinder head on the workshop crane and position it above the cylinder block.
CAUTION!
• Carefully lower the cylinder head.
• The tension- and guide rail must not be damaged.
• Pay attention to centering pins in cylinder block - arrows -.
• Observe cylinder head seal location, identification: Replacement part number must be visible from intake side.
CAUTION!
When turning the crankshaft, make sure the timing chain cannot damage any other components.
- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
- Set cylinder head in place.
- Insert cylinder head bolts and tighten 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 retighten the cylinder head bolts after repairs.
- Cylinder head, tightening sequence => [ Cylinder head tightening sequence ] Cylinder Head, Assembly Overview.
CAUTION!
When turning the crankshaft, make sure the timing chain cannot damage any other components.
- Rotate the vibration damper using the Counter Hold Tool (T10355) into the "OT" position - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
• The marked links of the timing chain must be positioned on the markings on the chain sprockets.
- Mount the camshaft timing chain: The markings drive chain/chain sprockets - arrows - must align.
- Turn the intake camshaft using the wrench in the - direction of the arrow - and mount the timing chain.
The rest of the installation is performed in reverse order of removal, noting the following:
- Change the engine oil
- Replace coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.