Volkswagen Workshop Service and Repair Manuals

Removing cylinder head cover –  Release pressure in high-pressure area → Chapter.   WARNING The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar). Prior to opening the high-pressure area, the fuel pressure in the high-pressure area must be reduced to a residual pressure of approx. 6 bar. The appropriate procedure is described in the chapter on releasing pressure in the high-pressure section → Chapter. –  With ignition switched off, disconnect battery earth strap. –  Drain coolant → Chapter.

–  Open spring-type clips and pull coolant hoses -1- and -2- off. –  Push catch -3- underneath coolant hoses and pull hoses upwards. –  Put down coolant hoses to rear.

–  Pull both hoses -1- off non-return valve. –  Unscrew securing bolt -2- and pull non-return valve out of cylinder head cover.

–  Remove all securing bolts from valve timing housing cover -1-. –  Remove valve timing housing cover.

–  Remove securing bolts -1- and remove coolant pipe bracket -2-.

–  Unscrew plug -arrow- from cylinder block. –  Screw locking pin -T10340- to stop into crankcase. –  Turn crankshaft in normal direction of rotation until the stop.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as described below. –  Remove locking pin. –  Turn crankshaft 1/4 revolution (90°) in normal direction of rotation. –  Screw locking pin -T10340- to stop into crankcase. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in normal direction of rotation until the stop.

Locking pin -T10340- locks crankshaft in direction of engine rotation.

–  Insert locking pin -T10414- to stop in cylinder head cover. –  Tighten securing bolt -1- hand tight.   Caution Sump only needs to be removed on vehicles ► 12.2009. In these vehicles, the timing chain can slip off the crankshaft chain sprocket during installation! –  Remove sump → Chapter.

–  Pull cover -1- off oil pump. All vehicles

–  Unscrew chain tensioner -arrow- for timing chain.

–  Loosen securing bolt -1- for camshaft chain sprocket. –  Hold camshaft chain sprocket with counterhold tool -T10172-. –  Remove camshaft sprocket together with securing bolt.

–  Place timing chain -1- on cast lug -arrow- in valve timing housing.   Note Cast lug on inside of valve timing housing prevents timing chain from falling down. –  Unscrew bolts -1- and remove retaining clip.

–  Pull connector -2- off charge air pressure sender -G31-. –  Unlock catches in -direction of arrow- and pull pressure pipe -3- first off throttle valve module -J338- and then off turbocharger. –  Open cover -4- and remove securing bolt. –  Use puller -T10112 A- to pull all spark plug connectors off spark plugs and put down ignition cables towards the rear.

–  Pull connector -1- and fuel supply line -2- off high-pressure pump.   Caution Only grasp high-pressure pump on housing when removing and installing! When the high-pressure piston spring package loosens the high-pressure pump will leak and must be replaced. –  Loosen union nuts -3- and remove line. –  Counterhold on bolted connections with an open-end spanner. –  Remove securing bolts from high-pressure pump and pull it out of cylinder head cover using tappet. –  Pull connector off injectors.

–  Remove bolts -arrows- and pull fuel rail off injectors. –  Remove turbocharger → Chapter. –  Disconnect connector off Hall sender -G40-. –  Pull out oil dipstick. –  Loosen cylinder head cover securing bolts from outside to inside, alternately and diagonally and remove. –  Carefully remove cylinder head cover. –  Remove sealant residues from cylinder head and cylinder head cover with a rotating brush, e.g. a hand drill with a plastic brush (wear eye protection). –  Clean sealing surfaces carefully. They must be free of oil and grease. –  Also prevent dirt and residual sealant from entering cylinder head. Removing and installing camshaft → Chapter. Fitting the cylinder head cover → Chapter