Cylinder Head

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Engine Sling -2024 A-
Engine Support -T10014-
Assembly Tool -T10352-
Counter Hold Tool -T10355-
Locking Pin -T40011-
Ignition Coil Puller -T40039-
Torque Wrench (5-50 Nm) -V.A.G 1331-
Torque Wrench (40-200 Nm) -V.A.G 1332-
Shop Crane - Load Cap = 700-1200KG -VAS 6100-
Engine Bung Set -VAS 6122-
Drip Tray for -VAS 6100- -VAS 6208-
Polydrive Bit and Drive Socket -T10070-

Removing

NOTE:

During installation, cable ties must be installed in the same location.

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

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

-- Loosen the hose clamp -2-.

Fig 1: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

-- Disconnect the electrical connector -arrow- and free up the electrical wire.

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.

Reduce pressure by covering the coolant expansion tank cap with a cloth and open carefully.

-- Open the coolant expansion tank cap.

-- Remove the right front wheel.

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

-- Remove the right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Loosen the clamps -items 1 and 2- and remove the charge air hose.

Fig 2: Identifying Charge Air Hose And Clamps

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

-- Remove the bolt -1- and remove the charge air pipe downward.

Fig 3: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolts -arrows-.

Fig 4: Identifying Air Guide Pipe And Bolts

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-- Lift the clamps -1 and 2- and remove the charge air pipe.

-- Disconnect the connectors -1 and 2- and free up the wire -arrows-.

Fig 5: Identifying Turbocharger Electrical Connectors

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Vehicles with All Wheel Drive (AWD)

Fig 6: Identifying, Tool -3247-, Bolts -1- And Heat Shield -A-

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-- Remove the right drive axle heat shield bolts -1- using the hex ball socket -3247- and remove the shield -A-.

Continuation for all Vehicles

Fig 7: Identifying Turbocharger Support And Bolts

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-- Remove the bolts -1 and 2- and remove the turbocharger support.

-- Remove the banjo bolt -2- and move the coolant line to the side.

Fig 8: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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Vehicles with Front Wheel Drive (FWD)

-- Remove the bolts -1- for the oil return line.

Vehicles with AWD

-- Remove the oil return line bolts from the crankcase.

Continuation for all Vehicles

-- Remove the bolt -3- for the oil supply line.

-- On vehicles with a noise generator: Remove the charge air pipe from the noise generator.

-- Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Fig 9: Identifying Camshaft Adjustment Valve And Bolts

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-- Disconnect the connectors from the ignition coils and free up the wiring harness.

-- Remove the ignition coils using the ignition coil puller -T40039-.

Fig 10: Identifying Ignition Coil Puller T40039 To Remove Ignition Coils

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-- Disconnect the hose for the crankcase ventilation - 1 -.

Fig 11: Identifying Crankcase Ventilation, Tightening Sequence

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-- Remove the bolts -arrows-.

-- Remove the charge air pipe bolt -arrow-.

Fig 12: Identifying Charge Air Pipe Bolt -Arrow- And Hose Clamp -2-

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-- Loosen the hose clamp -2- and remove the charge air pipe together with the crankcase ventilation.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

-- Disconnect the lines - 1 through 3- from the fuel transfer.

Fig 13: Identifying Breather Line, Vacuum Line & Fuel Supply Line

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Vent line -1-

Vacuum line -2-

Fuel supply line -3-

-- Disconnect the coolant line -arrow- from to the coolant expansion tank.

Fig 14: Identifying Coolant Line To Coolant Expansion Tank

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-- Remove the coolant hoses -arrows- from the coolant pipe.

Fig 15: Identifying Vacuum Line -1-, Ground Wire -3- And Bolt -4-

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-- Disconnect the ground wire -3- and remove the bolt -4-.

-- Disconnect the vacuum hoses -arrows-.

Fig 16: Identifying Vacuum Hoses

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-- Loosen the bolts -1 though 4- and remove the heat shield together with the coolant pipe.

Fig 17: Identifying Heat Shield Bolts

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-- Disconnect the oil supply line from the turbocharger -4-.

NOTE:

Remove the bolt -2- from the heat shield using a 6 mm -A- hex socket. The hex socket must be at least 5 cm -B- long. A socket that tapers to 6 mm at the tip is too wide.

Fig 18: Identifying 6mm Hex Socket -A-, 5cm Long -B-

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-- Disconnect the electrical connector -2- from the fuel pressure regulator valve -N276-.

Fig 19: Identifying High Pressure Fuel Pump And Fuel Pressure Regulator Valve Electrical Harness Connector

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Engine Code CBFA

Fig 20: Identifying Secondary Air Injection (Air) Solenoid Valve N112 Connector And Hose

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-- Disconnect the connector -A- and hose -B- from the secondary air injection solenoid valve -N112-.

-- Loosen the coolant pipe, remove the bolts -arrows-.

Fig 21: Identifying Coolant Pipe And Bolts

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Continuation for all Vehicles

-- Disconnect the coolant hose from the side connection on the cylinder head.

-- Disconnect the electrical connectors -1 through 4-.

Fig 22: Identifying EVAP Filter Vacuum Hose, Electrical Connectors And Electrical Cable

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-- Free up the wire -5-.

-- Disconnect the vacuum hose -6- leading to the canister.

GTI

Fig 23: Identifying Vent Line, Canister And Canister Catch

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-- Disconnect the vent line -1-, unlock the canister -A- and remove it -B-.

Continuation for all Vehicles

Fig 24: Identifying Vacuum Line And Electrical Connectors

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-- Disconnect the electrical connectors -1 - and pull the connectors out of the retainer.

-- Disconnect the electrical connectors -2 through 4-.

-- Disconnect the coolant line from the intake manifold, when doing this, remove the bolts -arrows-.

Fig 25: Identifying Intake Manifold Coolant Line Bolts

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-- Remove the intake manifold bracket by removing the nut -1- and bolt -2-.

Fig 26: Identifying Intake Manifold Bracket Mounting Nut And Bolt

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-- Remove the oil filter.

-- Disconnect the coolant hoses -arrows- and move them to the side.

Fig 27: Identifying Coolant Hoses

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-- Remove the bolts -arrows- and then the camshaft adjustment valve 1.

Fig 28: Identifying Camshaft Adjustment Valve And Bolts

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-- Remove the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER .

CAUTION:

The control valve has left hand threads.

-- Remove the control valve in the -direction of the arrow- using the assembly tool -T10352-.

Fig 29: Identifying Assembly Tool T10352 To Remove Control Valve

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-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 30: Identifying Bearing Bracket Bolts

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-- Rotate the vibration damper to the Top Dead Center (TDC) position -arrow- using the counter hold tool -T10355-.

Fig 31: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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The notch on the vibration damper must line up with the arrow mark -arrow- on the lower timing chain cover.
The marks -1- on the camshafts must point upward.

-- Carefully mark the position of the drive chain to the sprockets -A arrows- with a waterproof marker. Also mark the position of the drive chain to the guide rail -B arrows-. These marks are necessary for reinstallation.

Fig 32: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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-- Remove the plug -arrow-.

Fig 33: Locating Plug

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The locking wedge in the chain tensioner must be lifted in order to release the tension from the chain tensioner. Sand the end of the locking pin -T40011- down to a point. A screwdriver with a head approximately 1.5 mm wide can also be used.

CAUTION:

There is a risk of damaging the chain tensioner. Proceed very carefully.

-- Insert a screwdriver in the hole on the chain tensioner in the -direction of arrow 1- and lift the locking wedge in the chain tensioner.

Fig 34: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011

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-- In order to tension the chain tensioner, rotate the crankshaft opposite the engine rotation direction in the -direction of arrow 2- and secure it using a locking pin -T40011-.

NOTE:

The intake camshaft switches in the engine rotation direction.

-- Remove the guide pin -1- and guide the tensioning rail -2- downward.

Fig 35: Identifying Guide Tensioning Rail, Upper Guide Rai And Bolt

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-- Remove the upper guide rail -3- by unlocking the latch located in the center with a screwdriver and pushing the guide rail forward.

-- Remove the camshaft timing chain from the sprockets.

CAUTION:

Danger of damaging the valves, piston head and lower timing chain cover.

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turned further.
Panels are installed on the lower timing chain cover to prevent the chain from falling down. The panels can bend if the crankshaft is rotated when the chain is loose.

-- Turn the sealing plugs -arrows- counterclockwise 90° in the -direction of the arrow- and remove them.

Fig 36: Identifying Ball Head And Sealing Plug

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-- Remove the ball studs -1 and 2-

-- Remove the cap.

-- Remove the bolts -arrows-.

Fig 37: Identifying Cylinder Head - Loosening Sequence

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-- Remove the cylinder head bolts in sequence -1 through 5- using the polydrive bit and drive socket -T10070- until 2 are left.

NOTE:

To remove the cylinder head bolts, rotate the camshaft with a wrench if necessary.

Make sure all wires and hoses are disconnected!

Pay attention to the tensioning and guide rails when lifting the cylinder head.

-- Install the engine support -T10014- with each of the two small and large washers as illustrated.

Fig 38: Identifying Engine Support -T10014-, Washers, Bolt And Engine Sling -2024 A-

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-1- M8 washer, small.

-2- M8 washer, large. The outer diameter of the washer must be larger than the hole in the bracket.

-3- M8 x 30 bolt.

-- Install the engine sling -2024 A- to the engine support -T10014- and to the left front lifting eye on the cylinder head.

-- Secure the engine sling -2024 A- with the shop crane and gently lift the cylinder head.

Fig 39: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-

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-- Remove the last two cylinder head bolts.

CAUTION:

Carefully lift the cylinder head until the guide rail for the camshaft timing chain is free.
The tension and guide rails must not be damaged.

-- Lay the cylinder head on a soft surface, such as foam.

Installing

Tightening specifications, refer to CYLINDER HEAD OVERVIEW .

CAUTION:

The sealing surfaces could be damaged.

Carefully remove the sealant 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 cylinder head gasket leaking.

Carefully remove all grinding and sanding residue.
Only unpack 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 plastic base right before the cylinder head is installed to protect open valves.

Risk of damaging valves and piston heads after working on the valvetrain.

To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.

NOTE:

Replace the bolts which have been tightened to a torque angle.

Replace O-rings, seals and self-locking nuts.

Note the different sealant for the cylinder head sealing surfaces and bolts.

Secure all hose connections with hose clamps appropriate for the model.

When installing a replacement cylinder head, rotate the camshaft to TDC and mark the new sprockets exactly the same as on the old sprockets (note the factory colored mark on the sprockets).

When installing a replacement cylinder head, all of the contact surfaces between the hydraulic lash adjusters, roller rocker arms and cam running surfaces on the camshaft must be lubricated before installing the cylinder head cover.

The engine oil and coolant must be changed if the cylinder head or cylinder head gasket are replaced.

-- Support the cylinder head with the shop crane and position it above the cylinder block.

Fig 40: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-

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CAUTION:

Carefully lower the cylinder head.
The tensioning and guide rails must not be damaged.

Pay attention to the alignment pins -arrows- in the cylinder block.

Fig 41: Identifying Cylinder Block Centering Pins
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Observe the cylinder head gasket location, identification: The part number must be visible from the intake side.

CAUTION:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- In the event the crankshaft has been rotated in the meantime: Set the piston for cylinder 1 to TDC and rotate the crankshaft back again slightly.

-- Set the cylinder head in place.

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

NOTE:

In order to be able to tighten the cylinder head bolts, the intake camshaft must be turned with a wrench.

There is no requirement to tighten the cylinder head bolts after repairs.

-- Cylinder head bolt tightening sequence, refer to Figure.

CAUTION:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- Rotate the vibration damper to the TDC position -arrow- using the counter hold tool -T10355-.

Fig 42: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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The notch on the vibration damper must line up with the arrow mark -arrow- on the lower timing chain cover.

-- Mount the timing chain on the intake camshaft. The marks must align.

Fig 43: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

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-- Turn the intake camshaft in the -direction of the arrow- with a wrench until the timing chain is >>taut<<. Hold the intake camshaft secure in this position.

-- Mount the timing chain on the exhaust camshaft: the marks on the drive chain and sprockets -arrows A- and the drive chain and guide rail -arrows B- must align.

Fig 44: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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-- Install the upper guide rail -3-.

Fig 45: Identifying Guide Tensioning Rail, Upper Guide Rai And Bolt

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-- Move the tensioning rail -2- up and tighten the guide pin -1-.

NOTE:

If the marks on the drive chain and guide rail -B arrows- do not align even though the engine is at TDC, the drive chain has skipped on the crankshaft sprocket. Check the valve timing. Refer to VALVE TIMING, CHECKING . If the timing does not agree, the camshaft timing chain must be positioned again. Refer to CAMSHAFT TIMING CHAIN .

Fig 46: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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The rest of the installation is performed in reverse order of removal, noting the following:

-- Change the engine oil

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