volkswagen Workshop Repair Guides

Volkswagen Workshop Manuals

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Removing and installing cylinder head
   
Removing and installing cylinder head
Special tools and workshop equipment required
t  Lifting tackle -2024 A-
t  Bracket -T10014-
t  Assembly tool -T10352-
t  Engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB: assembly tool -T10352/1-
t  Counterhold tool -T10355-
t  Locking pin -T40011-
t  Puller -T40039-

   
t  Torque wrench -V.A.G 1331-
t  Torque wrench -V.A.G 1332-
t  Workshop hoist -VAS 6100-
t  Engine bung set -VAS 6122-
t  Drip tray for workshop hoist -VAS 6208-
t  Special wrench, long reach -T10070-

Not illustrated.
Valve lever -T40243-
Locking tool -T40267-
Camshaft clamp -T40271-
Removing
  Note
Fit cable ties in the original positions when installing.
–  Pull off engine cover → Chapter.
–  Remove air filter → Chapter.
   
–  Loosen hose clip -2-.
–  Remove bolt -4-.
–  Disconnect electrical connector -arrow- and move electrical wires clear.
  WARNING
Hot steam/hot coolant can escape - risk of scalding.
The cooling system is under pressure when the engine is hot.
Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure.
–  Open filler cap on expansion tank.
–  Remove front exhaust pipe with catalytic converter → Chapter.
–  Remove right front wheel.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.50.
–  Remove front part of right wheel housing liner → General body repairs, exterior; Rep. gr.66.
  A21-10161
–  Remove air pipe -item 1 and 2-.
–  Drain coolant → Chapter.
  A21-10051
–  Remove bolt -1- and take out air pipe downwards.
  A21-10161
–  Remove bolts -arrows-.
–  Remove air pipe (lift clips -items 1 and 2-).
  A21-10162
–  Separate electrical wiring connections -1 and 2- and place electrical wiring to one side -arrows-.
  A21-10186
Vehicles with auxiliary heater:
–  Unscrew bolts -1 and 2- and move coolant pipes to the left.
  A10-10777
Vehicles with four-wheel drive:
–  Unscrew bolts -1- for heat shield -A- above right axle shaft using hexagon key extension, 8 mm -3247-.
  N26-10338
All:
–  Remove bolts -1 and 2- and detach support for turbocharger.
  A21-10187
–  Remove banjo bolt -2- and move coolant pipe clear to one side.
Vehicles with front-wheel drive
–  Remove bolts -1- on oil return pipe.
Vehicles with four-wheel drive:
–  Undo and remove bolts of oil return line at crankcase.
All vehicles:
–  Remove bolt -3- on oil supply pipe.
–  Only vehicles with sound generator: Remove charge air duct to sound generator.
  A21-10188
–  Detach connector from inlet camshaft control valve 1 -N205--1-.
–  Disconnect electrical connectors at ignition coils and place wiring harness to one side.
  A15-10442
–  Remove ignition coils using puller -T40039-.
  A28-0074
Engine codes BZB, CAWA, CAWB, CGYA, CDAA:
–  Press release tabs, detach air hose -1- and swivel to side.
–  Unscrew bolt -arrow- for air pipe.
–  Loosen hose clip -2- and remove air pipe.
  N21-10192
–  Disconnect crankcase breather hose -1-.
–  Remove bolts -arrows- and remove crankcase breather.
  A15-10473
Engine codes CBFA, CCTA, CCTB:
–  Disconnect crankcase breather hose -1-.
–  Unscrew bolts -arrows-.
  A15-10473
–  Unscrew bolt -arrow- for air pipe.
–  Loosen hose clip -2- and remove air pipe together with crankcase breather.
All:
  WARNING
Fuel supply line is pressurised. Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
  N21-10192
–  Detach lines -1 to 3- from the fuel transfer point.
   1) Breather pipe
   2) Vacuum line (only CBFA, CCTA, CCTB)
   3) Fuel supply line
  N10-10199
–  Disconnect coolant line to coolant expansion tank -arrow-.
  A21-10043
–  Remove coolant hoses -arrows- from coolant pipe.
–  Unbolt earth cable -3- and slacken bolt -4-.
  N21-10172
–  Pull off vacuum hoses -arrows-.
  N10-10269
–  Loosen bolts -1…4- and remove heat shield together with coolant pipe.
–  Remove oil supply pipe from turbocharger -4-.
  Note
  N21-10173
On 2.0 l engines, unscrew bolt -2- from heat shield using 6 mm -A- hexagon socket. The hexagon must be at least 5 cm -B- long. A socket which tapers to 6 mm at the tip is too thick.
  N15-10449
–  Pull electrical connector -2- from fuel pressure regulating valve -N276-.
  A24-10436
Engine code CBFA:
–  Pull connector -A- and hose -B- from secondary air inlet valve -N112-.
  N26-10355
–  Loosen coolant pipe by unscrewing bolts -arrows-.
All:
–  Pull coolant hose from lateral union on cylinder head.
  N26-10356
–  Disconnect electrical connectors -1 … 4-.
–  Place electrical cable -5- to one side.
–  Detach vacuum line -6- leading to activated charcoal filter.
  A15-10453
Golf, Scirocco:
–  Pull off breather line -1-, release activated charcoal filter -A- and remove upwards -B-.
  N13-10335
All:
–  Disconnect electrical connectors -1- and detach connectors from retainer.
–  Disconnect electrical connectors -2 … 4-.
  A15-10452
–  Detach coolant pipe from intake manifold; to do so, unscrew bolts -arrows-.
  A24-10446
–  Remove intake manifold support (remove securing nut -1- and bolt -2-).
–  Remove oil filter.
  A24-10447
–  Disconnect coolant hoses -arrows- and move clear.
  A15-10455
–  Unscrew bolts -arrows- and remove inlet camshaft control valve 1 -N205-.
–  Remove timing chain cover (top) → Chapter.
  Caution
The timing valve has a left-hand thread.
  A15-10442
–  Remove control valve using assembly tool -T10352- (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB: assembly tool -T10352/1-) in direction of -arrow-.
  A15-10443
–  Remove bolts -arrows- and detach bearing saddle.
  A15-10444
–  Turn vibration damper to »TDC« position -arrow- using counterhold -T10355-.
l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).
l  The markings -1- on the camshafts must face upwards.
  A15-10451
–  Mark positions of chain sprocket markings -1- on camshaft timing chain and cylinder head -arrows- using a permanent felt tip marker.
–  Also mark alignment of camshaft timing chain -2- relative to guide rail of camshaft timing chain using a permanent felt tip marker.
  A15-11400
–  Remove sealing plug -arrow-.
  A15-10447
–  Unscrew bolts -arrows-.
  A15-11390
–  Unscrew bolt -arrow-.
  A15-11401
Depending on model, two different chain tensioners may be installed:
Variant 1
–  Screw in valve lever -T40243--arrows-.
–  Insert scriber or suitable screwdriver in hole of chain tensioner in direction of -arrow 1- and lift locking element. Then, slowly push valve lever -T40243- in -direction of arrow 2- and hold it in that position.
  A15-11397
–  Secure chain tensioner with locking pin -T40011-.
  A15-11398
Variant 2
–  Screw in valve lever -T40243--arrows-.
–  Press together circlip -arrow- of chain tensioner. Then, slowly push valve lever -T40243- in -direction of arrow- and hold it in that position.
  A15-11393
–  Secure chain tensioner with locking pin -T40267-.
All
–  Remove valve lever -T40243-.
  A15-11394
–  Bolt camshaft clamp -T40271/2- to cylinder head and insert it in -direction of arrow 2- between splines of chain sprocket. If necessary turn inlet camshaft in -direction of arrow 1- using spanner.
  A15-11402
–  Remove bolt -1- and guide tensioning rail -2- downwards.
  A15-11384
–  Bolt camshaft clamp -T40271/1- to cylinder head.
–  Turn exhaust camshaft in -direction of arrow 1- using spanner and insert camshaft clamp -T40271/1- in -direction of arrow 2- between splines of chain sprocket.
  A15-11423
–  Use screwdriver to release catch and press off top guide rail -1- forwards.
–  Remove camshaft timing chain from camshaft sprockets.
  Caution
Avoid damage to valves and piston crowns.
Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head.
  A15-11386
–  Turn sealing plugs -arrows- 90° anti-clockwise -arrow- and remove.
–  Ball head -1 ... 2-.
–  Remove filler cap.
  A15-10556
–  Unscrew bolts -arrows-.
–  Unscrew cylinder head bolts using polydrive bit and socket -T10070- in sequence -1 … 5-.
  Note
t  Make sure all hoses/pipes and wiring on component are removed.
t  Ensure tensioning rail and guide rail are not damaged when lifting off cylinder head.
–  Remove cylinder head.
–  Place cylinder head onto soft surface (foam plastic).
Installing
l  Specified torques → Chapter.
  Caution
Avoid damage to sealing surfaces.
t  Carefully remove sealant residue from cylinder head and cylinder block.
t  Ensure that no long scores or scratches are made on the surfaces.
Avoid damage to cylinder block.
No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
t  Carefully remove remains of emery and abrasives.
t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted.
t  Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket.
Avoid damage to open valves.
When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on valve gear.
Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.
  Note
t  Renew bolts tightened with specified tightening angle.
t  Renew self-locking nuts as well as gaskets, seals and O-rings.
t  When installing a replacement cylinder head, the contact surfaces between hydraulic compensation elements, roller rocker fingers and cams must be oiled before installing the camshafts.
t  Hose connections and air duct pipes must be free of oil and grease before assembly.
t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue.
t  In order to be in a position to securely attach the charge air hoses on their connections, the worm screws of the used hose clips have to the sprayed with penetrating spray before installing.
t  When cylinder head or cylinder head gasket is renewed, the entire coolant and the engine oil must be changed.
Procedure for new cylinder head
  A15-10474
–  Mark alignment of camshaft sprockets relative to camshaft clamp -T40271/1- and camshaft clamp -T40271/2--arrow-.
  A15-11386
–  Turn inlet camshaft in -direction of arrow 1- using spanner, remove camshaft clamp -T40271/2- in -direction of arrow 2- from between splines of chain sprocket and bring camshaft into rest position.
–  Remove camshaft clamp -T40271/2-.
  A15-11425
–  Turn exhaust camshaft in -direction of arrow 1- using spanner, remove camshaft clamp -T40271/1- in -direction of arrow 2- from between splines of chain sprocket and bring camshaft into rest position.
–  Remove camshaft clamp -T40271/1-.
–  Transfer the previously marked markings from the old camshafts onto the new camshafts.
  A15-11424
–  Bolt camshaft clamp -T40271/2- to cylinder head.
–  Turn inlet camshaft in -direction of arrow 1- until marking -3- aligns with camshaft clamp -T40271/2-.
–  Insert camshaft clamp -T40271/2- in -direction of arrow 2- between splines of chain sprocket.
  A15-11432
–  Bolt camshaft clamp -T40271/1- to cylinder head.
–  Turn exhaust camshaft in -direction of arrow 1- until marking -3- aligns with camshaft clamp -T40271/1-.
–  Insert camshaft clamp -T40271/1- in -direction of arrow 2- between splines of chain sprocket.
All
  A15-11433
–  Position cylinder head gasket.
t  Note position of centralising pins in cylinder block -arrows-.
t  Check installation position of cylinder head gasket. The part number should be legible from the inlet side.
  WARNING
When turning the crankshaft, ensure that no components are damaged by the timing chain.
–  If crankshaft is turned in the meantime, position piston of No. 1 cylinder at TDC and turn crankshaft back slightly.
–  Fit cylinder head.
–  Insert and hand-tighten cylinder head bolts.
–  Tightening sequence for cylinder head → Fig..
  Note
After repair work it is not necessary to retighten the cylinder head bolts.
  WARNING
When turning the crankshaft, ensure that no components are damaged by the timing chain.
  A15-0135
–  Turn vibration damper to „TDC“ position -arrow- using counterhold -T10355-.
l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).
  A13-10442
–  Fit camshaft timing chain on chain sprockets. To do this, align markings on chain links -arrows- with markings on chain sprockets -1-.
–  Install upper guide rail -2-.
  A15-11434
–  Turn exhaust camshaft in -direction of arrow 1-, remove camshaft clamp -T40271/1- in -direction of arrow 2- from between splines of chain sprocket and relieve tension from camshaft.
–  Remove camshaft clamp -T40271/1-.
  A15-11435
–  Move tensioning rail -2- upwards and screw in bolt -1-.
  A15-11384
–  Turn inlet camshaft in -direction of arrow 1-, remove camshaft clamp -T40271/2- in -direction of arrow 2- from between splines of chain sprocket and relieve tension from camshaft.
–  Remove camshaft clamp -T40271/2-.
  A15-11436
–  Check valve timing. Markings on camshaft timing chain and cylinder head -arrows- must align with markings on chain sprockets -1-.
–  Markings on camshaft timing chain and on guide rail of camshaft timing chain -2- must also align.
–  Notch on vibration damper must align with marking on lower timing chain cover -3-.
  A15-11437
–  Attach bearing saddle and screw in bolts -arrows- hand-tight.
–  Depending on model, remove locking pin -T40011- or locking pin -T40267-.
–  Tighten bolts -arrows- for bearing saddle → Chapter.
  A15-10444
–  Screw in bolt -arrow-.
–  Install timing valve → Item.
–  Use spanner to turn inlet camshaft in direction of -arrow- and fit timing chain.
Remaining installation steps are carried out in reverse sequence; note the following:
–  Change engine oil.
–  Fill cooling system with fresh coolant → Chapter.
  A15-11401

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