Cylinder Head Cover

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

Torque Wrench (5-50 Nm) V.A.G 1331
Hose Clip Pliers VAS 6362
Socket T40055
Ratchet, Reversible V.A.G 1331/1
Engine Bung Set VAS 6122

CAUTION:

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

Always follow these instructions before and during work.

NOTE:

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

Removing

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 protective strip.

-- Disconnect the connectors from the fuel injectors -A-, the exhaust pressure sensor 1 -G450- -B- and the fuel pressure sensor -G247- -C-.

Fig 1: Identifying Fuel Injectors -A-, Exhaust Pressure Sensor 1 -G450- -B- And Fuel Pressure Sensor -G247- -C-

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-- Remove the coolant line bolts -arrows- from the intake manifold and lay the line in front of the intake manifold.

-- Unclip the wiring harness for the glow plugs from the wiring guide.

CAUTION:

Always follow the procedure "glow plug connectors, disconnecting and installing".

-- Disconnect the glow plug connectors. Refer to GLOW PLUG CONNECTOR, DISCONNECTING AND CONNECTING .

-- Remove the fuel return line bolt from the intake manifold.

-- Reposition the hose clamp -arrow- using hose clip pliers VAS 6362 and remove the line from the fuel rail.

Fig 2: Identifying Hose Clamp -Arrow-

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-- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).

-- Cover the return line connections with a cloth.

-- Remove the fuel return line connections on the fuel injectors. Pull them upward to release them -arrow-.

Fig 3: Identifying Fuel Return Line Connections On Fuel Injectors

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NOTE:

Follow the rules of cleanliness.

Do not let any dirt to get into the disconnected return lines or into the connections for the fuel injection units.

-- Reposition the hose clamp using hose clip pliers VAS 6362 and remove the fuel return line.

-- Reposition the hose clamp -4- using hose clip pliers VAS 6362 and remove the fuel return line at the high pressure fuel pump.

Fig 4: Identifying Hose Clamp -4-

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-- Seal the lines so that the fuel system is not contaminated by dirt, etc.

-- Remove the fuel return line and lay the lines in front of the intake manifold.

-- Disconnect the connector from the charge pressure actuator position sensor -G581- -arrow- at the turbocharger vacuum diaphragm and guide the line out of the retainers.

Fig 5: Identifying Connector To Charge Pressure Actuator Position Sensor -Arrow-

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-- Disconnect the connector from the fuel pressure regulator valve -N276- -arrow-.

Fig 6: Identifying Connector To Fuel Pressure Regulator Valve -Arrow-

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-- Remove the line guide on the fuel rail and lay it aside.

-- Remove the vacuum hose from the cylinder head cover.

-- Remove the remaining vacuum hoses from the bracket on the cylinder head cover.

-- Disconnect the connector -1- from the engine coolant temperature sensor on radiator outlet -G83-, open the clips -arrows- and remove the upper toothed belt guard.

Fig 7: Identifying Connector -1- And Clips -Arrows-

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-- Remove the crankcase ventilation hose between the intake tube and the cylinder head cover.

NOTE:

The crankcase ventilation hose is destroyed when it is removed.

-- Remove the high pressure fuel line between the high pressure fuel pump and fuel rail.

-- Remove the high pressure fuel lines between the fuel rail and fuel injectors.

-- Remove the bolts -arrows- and the fuel rail.

Fig 8: Identifying Bolts -Arrows- And Fuel Rail

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-- Remove the fuel injectors. Refer to FUEL INJECTOR .

-- Remove the cylinder head cover bolts in sequence -7 through 1-.

Fig 9: Identifying Head Cover Bolts -1 Through 7- Tightening Sequence

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-- Remove the cylinder head cover.

Installing

Install in reverse order of removal. When doing this note the following:

Replace the cylinder head cover gasket if it leaks or is damaged.
When installing the high pressure line or fuel lines, make sure no dirt or contaminants enter the fuel system.
Only remove the sealing plugs right before installing the fuel lines.
Do not change the angles of the high pressure lines
Make sure line connections are securely fastened.
Do not swap the supply and return lines.

-- First, tighten the cylinder head cover bolts by hand in sequence -1 through 7-.

Fig 10: Identifying Head Cover Bolts -1 Through 7- Tightening Sequence

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-- Tighten the cylinder head cover bolts in sequence -1 through 7- to specification.

Tightening specification, see -item 14- in the CYLINDER HEAD COVER OVERVIEW .

-- Install the upper toothed belt guard.

-- Make sure the upper toothed belt guard is clipped to the cylinder head cover correctly.

Fig 11: Identifying Upper Toothed Belt Guard

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NOTE:

The camshaft gear is not shown in the illustration.

-- Press the upper toothed belt guard in the area with the clips -arrows- against the cylinder head cover until the clips engage with each other. Use a screwdriver to press the guard if necessary.

-- Check the clearance between the hub and the upper toothed belt guard.

-- Tighten the high pressure line union nuts by hand.

-- Make sure the high pressure line is free of tension.

-- Use the torque wrench (5-50 Nm) V.A.G 1331 with the ratchet, reversible V.A.G 1331/1 and the socket T40055 to tighten the high pressure line.

Fig 12: Identifying Torque Wrench V.A.G 1331T, Reversible V.A.G 1331/1 And Socket T40055

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Tightening Specifications

Cylinder head cover overview, refer to CYLINDER HEAD COVER OVERVIEW .
Fuel system overview, refer to FUEL RAIL AND INJECTORS OVERVIEW .

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