Cylinder Head

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Guide Pins & Handle - 1112 mm 3070
Diesel Injection Pump Locking Pin 3359
Crankshaft Stop T10050
Camshaft Gear Counter-Holder T10051
Puller T10052
Socket Insert XZN 10 T10385
Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Drip Tray for VAS 6100 VAS 6208
Engine Bung Set VAS 6122

CAUTION:

Follow the safety precautions when working on the diesel direct injection system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

NOTE:

Toothed belt overview. Refer to TOOTHED BELT OVERVIEW .

Cylinder head cover overview. Refer to CYLINDER HEAD COVER OVERVIEW .

Cylinder head overview. Refer to CYLINDER HEAD OVERVIEW .

Turbocharger and exhaust manifold with attachments overview. Refer to TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW .

Charge air cooler components overview. Refer to CHARGE AIR COOLER COMPONENT OVERVIEW .

Intake manifold and attachments overview. Refer to INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW .

Particulate filter with NOx reduction catalyst overview. Refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Exhaust Gas Recirculation (EGR) system overview. Refer to EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .

Hose connections are secured with either spring type or clamp type clamps.

Always replace clamp-type clamps with spring type clamps.

Hose clip pliers VAS 6362 or hose clip pliers VAS 6340 are recommended for installing spring type clamps.

All cable ties which are opened or cut off when removing the cylinder head, must be replaced in the same position when installing the cylinder head.

Removing

NOTE:

To perform the procedure, the battery ground cable must be disconnected. See if a coded radio is installed. If so, obtain the anti-theft code beforehand.

WARNING:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
For example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum lines.
Ensure sufficient clearance to all moving or hot components.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING .

CAUTION:

Electronic components could be destroyed when the battery is disconnected:

Follow the required steps when disconnecting the battery.

-- Turn off the ignition and disconnect the ground cable -arrow- from the battery. Refer to Removal and Installation .

Fig 1: Identifying Battery And Ground Cable

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-- Remove the battery, the battery tray bolts -arrows- and tray.

Fig 2: Identifying Battery Holder Bolts

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-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Remove the toothed belt from the camshaft. Refer to TOOTHED BELT .

-- Remove the camshaft gear and hub. Refer to CAMSHAFTS .

-- Disconnect the connector from the exhaust gas recirculation vacuum regulator solenoid valve -N18- -1- and the throttle valve control module -J338- -3-.

Fig 3: Identifying Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve -1-, Throttle Valve Control Module -J338- -3- And Clamp -4-

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-- Loosen the clamp -4- and remove the charge air hose.

-- Remove the oil dipstick tube bracket -arrow-.

-- Remove the fan shroud and fans. Refer to FAN SHROUD AND FANS .

-- Remove the bolts -arrows- from the charge air pipe and disconnect the connector -1- from the charge air pressure sensor -G31-.

Fig 4: Identifying Connector -1-, Clamp -2 And Coolant Hose -3-

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-- Open the clamp -2-, free up the coolant hose -3- and remove the charge air pipe.

Fig 5: Identifying Connector -1-, Clamp -2 And Coolant Hose -3-

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-- Remove the oil supply line. Refer to OIL SUPPLY LINE TO TURBOCHARGER .

-- Unclip the Engine Control Module (ECM) wiring harness from the wiring guide -arrow-.

Fig 6: Identifying Engine Control Module (ECM) Wiring Guide -Arrow-

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-- Remove the vacuum pump. Refer to VACUUM PUMP .

-- Disconnect the connector from the charge pressure actuator position sensor -G581- -2- at the turbocharger vacuum diaphragm.

Fig 7: Identifying Connector To Charge Pressure Actuator Position Sensor -G581- -2- And Vacuum Hose -3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the vacuum hose -3- from the vacuum diaphragm on the turbocharger.

-- Disconnect the >>black<< connector for the exhaust gas temperature sensor 1 -G235- -2- at the plenum chamber bulkhead.

Fig 8: Identifying >>Black<< Connector To Exhaust Gas Temperature Sensor 1 -G235- -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the wire out of the mount on the plenum chamber bulkhead and on the turbocharger.

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig 9: Identifying Protective Cap For Drive Axle On Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the charge air pipe bolts and the hose from the turbocharger.

-- Mark the installed position of the exhaust gas temperature sensor 1 and remove it.

-- Remove the heat shield and disconnect the connector from the exhaust pressure sensor 2 -G451-. Refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

-- Remove the control wire between the EGR housing and the exhaust pressure sensor 2. Refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

-- Remove the bolts and bracket with the exhaust pressure sensor 2 and lay them aside (the control wire to the particulate filter remains connected).

-- Remove the lower bracket for the particulate filter.

NOTE:

Remove the nuts above the bracket using wrench SW13 T10384.

-- Remove the EGR filter.

-- Disconnect the connector -arrow- from the engine coolant temperature sensor -G62- and guide the wire out.

Fig 10: Identifying Connector -Arrow- To Engine Coolant Temperature Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the particulate filter from the upper bracket and remove the bracket from the cylinder head.

-- Remove the clamp between the particulate filter and turbocharger.

-- Remove the banjo bolt from the turbocharger support.

-- Remove the stud bolt from the turbocharger support.

-- Rotate the lower section of the support 90° and remove the support downward from the upper section.

-- Remove the coolant hoses at the cylinder head coolant connections.

-- Remove the bolt -arrow- from the rear toothed belt guard.

Fig 11: Identifying Nut To Toothed Belt Tension

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-- Remove the nut from the toothed belt tension.

-- Disconnect the camshaft position sensor -G40- connector -arrow-.

Fig 12: Identifying Camshaft Position Sensor -G40- Connector -Arrow-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Remove the cylinder head bolts in sequence -1 through 10-.

Fig 13: Identifying Cylinder Head Bolts Loosening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

A second technician is needed when removing the cylinder head.

The toothed belt tensioner is pulled off the stud bolt when lifting the cylinder head off.

The turbocharger oil return line is pulled out of the support when lifting the cylinder head off.

Make sure all necessary electrical wires are disconnected!

-- Raise the cylinder head at the transmission side first and guide it back out of the toothed belt guard. Be careful not to let the toothed belt tensioner fall.

-- Lay the cylinder head down so that the oil return line is not bent. Place a wooden block under the exhaust manifold if necessary.

Installing

CAUTION:

The sealing surfaces could be damaged:

Carefully remove any sealant residue 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 the cylinder head gasket leaking:

Carefully remove all grinding and sanding residue.
Only unpack a 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 accompanying plastic base immediately before installing to protect the 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.
Before installing, check if the oil return pipe coupling element is bent and therefore stretched. If that is the case, tiny cracks can form that can lead to leaks. Replace the oil return pipe before installing the cylinder head if necessary.

NOTE:

Always replace cylinder head bolts.

Replace the gaskets, seals, self-locking nuts and clamps.

Carefully remove residual sealant from the cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.

Thoroughly remove all sanding and grinding residue.

Only unpack the new cylinder head gasket immediately prior to installation.

-- Before installing the cylinder head, remove the crankshaft stop T10050 and rotate the crankshaft back opposite the engine rotation direction until all of the pistons are nearly even under Top Dead Center (TDC).

-- Place the cylinder head gasket with the identification upward.

-- Slide the guide pins3070 into the outer bores on the intake side to center.

Fig 14: Identifying Installed Guide Pins

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The tensioner must be placed on the studs when positioning the cylinder head.

-- Install the cylinder head, insert the eight cylinder head bolts and tighten them by hand.

-- Remove the guide pins 3070 through the bolt holes using the guide pin handle. Insert the cylinder head bolts.

-- Tighten the cylinder head bolts in the sequence -1 through 10- indicated, in four stages as follows:

Fig 15: Identifying Cylinder Head Bolt Tightening Sequence

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Tighten the bolts using a torque wrench:
Stage I - 35 Nm

Stage II - 60 Nm
Tighten the bolts further using a ratchet:
Stage III - an additional 90° (1/4) turn

Step IV - an additional 90° (1/4) turn

-- Secure the toothed belt guard on the back of the cylinder head.

Tightening specifications, see -item 14- in the TOOTHED BELT OVERVIEW .

-- Install the camshaft gear and hub. Refer to CAMSHAFTS .

-- Secure the camshaft and the high pressure fuel pump using the diesel injection pump locking Pin 3359.

-- Rotate the crankshaft in engine rotation direction and secure the crankshaft using the crankshaft stop T10050.

Fig 16: Identifying Crankshaft Stop T10050

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install and tension the toothed belt. Refer to TOOTHED BELT .

The additional numbered steps must be followed to ensure the particulate filter with the NOx reduction catalytic converter is installed correctly:

NOTE:

After installing the particulate filter with NOx reduction catalytic converter, make sure it is free of tension.

Always replace self-locking nuts, seals, gaskets and clamps.

CAUTION:

The coupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:

Do not bend the coupling element more than 10°.
Do not stretch the coupling element.
Do not damage the wire mesh on the coupling element.

-- Position the lower bracket with the nuts on the cylinder block and on the particulate filter. (Do not tighten the nuts.)

-- Position the new clamp with a new gasket between the particulate filter and turbocharger (do not tighten the clamp):

Make sure the clamp is in the correct installed position. Refer to one of the following:
Engine Code CBEA, refer to MUFFLER OVERVIEW .
Engine Code CJAA, refer to MUFFLER OVERVIEW .

-- Install the EGR filter -item 9- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .

-- Position a new clamp between the particulate filter and EGR filter (do not tighten the clamp):

Make sure the clamp is in the correct installed position. Refer to one of the following:
Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

-- Position the particulate filter on the upper bracket with the bolt. (Do not tighten the bolt.)

-- Tighten the mounting elements in the following sequence:

-- Clamp between the particulate filter and turbocharger.

-- Lower bracket to the cylinder block:

-- Lower bracket to the particulate filter:

-- Upper bracket to the particulate filter:

-- Upper bracket to the cylinder head:

-- Clamp between the particulate filter and EGR filter:

Tightening specifications, refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Further installation is performed in reverse order. When doing this note the following:

Replace the self-locking nuts and seals.
Position the charge air pipe connecting hose before securing the turbocharger.
Note the exhaust gas temperature sensor 1 installed position.
Replace the banjo bolt with the turbocharger support gaskets and oil return pipe O-rings.
Do not stretch the oil return pipe coupling element when installing the turbocharger support.
Make sure lines connections are securely fastened.

-- Install the cylinder head cover. Refer to CYLINDER HEAD COVER

-- Install the right drive axle heat shield and bolts -arrows-. Refer to DRIVE AXLE HEAT SHIELDS .

Fig 17: Identifying Protective Cap For Drive Axle On Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tightening Specifications

TOOTHED BELT OVERVIEW
CYLINDER HEAD COVER OVERVIEW
CYLINDER HEAD OVERVIEW
TURBOCHARGER AND EXHAUST MANIFOLD WITH ATTACHMENTS OVERVIEW .
CHARGE AIR COOLER COMPONENT OVERVIEW
INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW
Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW

NOTE:

Electrical connections and routings. Refer to DESCRIPTION AND OPERATION .

-- Observe the notes after reconnecting the battery. Refer to REMOVAL AND INSTALLATION .

-- Fill with coolant. Refer to DRAINING AND FILLING .

-- Fill the fuel system. Refer to FUEL SYSTEM, FILLING AND BLEEDING .