Cylinder head, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE:

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

Remove engine cover.
Check whether a coded radio is installed. If so, obtain anti-theft coding.
With ignition switched off disconnect battery Ground strap.
Remove intake manifold → Cylinder head cover, removing and installing , Removing and installing cylinder head cover.

Fig 1: Locating Engine Coolant Temperature Sensor G62

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Disconnect 4-pin connector - arrow - from Engine Coolant Temperature (ECT) sensor G62 with Engine Coolant Temperature sensor Engine Coolant Temperature (ECT) Gauge Sensor G2.
Drain coolant → Cooling system, draining and filling .
Remove coolant thermostat housing → Components of cooling system, engine side , Parts of cooling system, engine side.

Fig 2: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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Turn crankshaft on vibration damper securing bolt in engine direction of rotation to TDC cyl. 1 - arrow -.
Remove cylinder head cover → Cylinder head cover, removing and installing .

Fig 3: Locating Camshaft Roller Chain Tensioner

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Remove camshaft roller chain tensioner - arrow -.

Fig 4: Identifying CMP Sensor G40, CMP Sensor 2 G163 And Connectors

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Disconnect connections from following components on cover:

Camshaft Position (CMP) sensor G40 - 1 - ,
Camshaft Position (CMP) sensor 2 G163 - 2 - ,
Valve -1- for camshaft adjustment N205 - 3 - ,
Camshaft adjustment valve 1 (exhaust) N318 - 4 -.

NOTE:

Mark connector and component before disconnecting.

Release and free wiring harness.
Remove camshaft cover → Cover, removing and installing .

Fig 5: Identifying Markings On Roller Chains

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Mark roller chains before removing (e.g. with paint, - arrow - pointing in direction of rotation).

NOTE:

Do not mark chain with a punched mark, notch or similar!

Separate front exhaust pipe from exhaust manifold → Exhaust system components, servicing , Removing and installing parts of exhaust system.

Fig 6: Locating Groove In Intermediate Shaft Chain Sprockets

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Check timing settings: When correctly positioned at TDC cyl. 1, a groove - arrow - can be seen in intermediate shaft chain sprockets

NOTE:

This condition only occurs at every 2nd TDC position.

If the notch cannot be seen:

Turn crankshaft one full turn further in engine direction of rotation.

NOTE:

When the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand instead of with the chain tensioner.

Fig 7: Camshaft Bar T10068 Engaged In Both Shaft Grooves

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The Camshaft bar T10068 must engage in both shaft grooves.

NOTE:

If the camshaft bar cannot be installed, turn the crankshaft in engine direction of rotation until approx. 5 mm past the TDC setting for No. 1 cyl. (dependent on drive chain tolerances).

Check setting marks of camshaft timing adjusters with marks on control housing:

Fig 8: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing

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Marks - A - and - B - on camshaft timing adjusters must align with notches - arrows - on control housing - C -.

Distance between tooth - 1 - and tooth - 2 - of camshaft timing adjuster must be exactly 16 rollers of camshaft roller chain.

NOTE:

Illustration shows a cover which has been removed.

First remove exhaust camshaft timing adjuster.
Remove camshaft timing adjuster together with camshaft roller chain from intake camshaft.

Fig 9: Camshaft Counter Support Area

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NOTE:

Counter support on camshaft with a 32 mm open end wrench - arrow -. Camshaft bar T10068 must not be installed when loosening or tightening camshaft timing adjuster.

Fig 10: Guide Rail Securing Bolts And Guide Rail

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Remove guide rail securing bolts - arrow - and remove guide rail - 1 -.
Place camshaft roller chain to side.

Fig 11: Socket Head Bolts Removal Sequence

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Loosen socket head bolts in sequence given and then remove.

NOTE:

Use tool 3452 for Polydrive cylinder head bolts.

Carefully lift cylinder head off.