Cylinder Head: Notes

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Camshaft bar T10068A
Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332
Spring type clip pliers VAS 5024A
Puller for ignition coil T10095A
Lifting tackle 3033
Shop crane VAS 6100

Requirements

The engine must be no more than warm to touch.

Removing

CAUTION:

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

Route lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

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

-- Check whether a coded radio is installed. If necessary, obtain the antitheft code.

With the ignition switched off, disconnect the battery ground cable. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Remove the air filter and connecting hose. Refer to AIR FILTER ASSEMBLY OVERVIEW .

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

-- Remove the front bumper cover. Refer to Removal and Installation .

-- Bring the lock carrier into the service position. Refer to Description and Operation .

WARNING:

Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.

-- Disconnect the fuel supply line -4- and catch any leaking fuel with a cloth.

Fig 1: Identifying Fuel Supply Line, Vent Line & Vacuum Line

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-- Disconnect the vent line -2- and vacuum line -3-.

NOTE:

Press in the securing ring to disengage the fuel line.

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

-- Unclip the fuel lines at the cylinder head cover.

-- Remove the intake manifold. Refer to INTAKE MANIFOLD .

-- Remove the Secondary Air Injection (AIR) combination valves and intake manifold support from the shield. Refer to SECONDARY AIR INJECTION SYSTEM COMPONENTS ASSEMBLY OVERVIEW .

NOTE:

Before disconnecting the harness electrical connectors, mark the allocation to the component.

-- Disconnect the electrical connectors from the Camshaft Position (CMP) sensor -1- and the CMP sensor 2 -2-.

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

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-- Disconnect the electrical connectors -3 and 4-.

-- Remove the front exhaust pipe from the exhaust manifolds. Refer to EXHAUST MANIFOLD AND FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS ASSEMBLY OVERVIEW .

-- Rotate the crankshaft using the vibration damper bolt in the direction of engine rotation to the Top Dead Center (TDC) cylinder 1 marking -arrow-.

Fig 3: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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-- Disconnect the 2 pin electrical connector -arrow- from the Engine Coolant Temperature (ECT) sensor.

Fig 4: Identifying Engine Coolant Temperature (ECT) Sensor G62 Electrical Harness Connector

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-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- Remove the coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING ASSEMBLY OVERVIEW .

-- Remove the coolant hose below from the cylinder head to heater unit heat exchanger.

-- Remove the coolant pipes on the cylinder head and from the auxiliary heater on the cylinder block, if applicable. Refer to COOLING SYSTEM ASSEMBLY OVERVIEW, ENGINE SIDE .

-- Disconnect the engine wiring harness electrical connector and the combination valve pressure hose from the cylinder head.

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

-- Remove the chain tensioner for the camshaft roller chain -arrow-.

Fig 5: Locating Camshaft Roller Chain Tensioner

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-- Remove the timing chain cover bolts -arrows- and the cover.

Fig 6: Identifying Mounting Bolts For Cover

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NOTE:

Counter hold only with a 32 mm open end wrench on the camshaft -arrow-. The T10068A must not be inserted when tightening or loosening the camshaft adjuster bolts.

Fig 7: Locating Counter-Hold Area On Camshaft

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-- Remove the exhaust camshaft adjuster.

-- Remove the guide rail bolts -arrows- and the guide rail -1-.

Fig 8: Locating Guide Rail & Bolts

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-- Place the camshaft roller chain aside.

-- Loosen and remove the cylinder head bolts in the sequence shown starting from the outside working toward the inside.

Fig 9: Identifying Cylinder Head Bolts Removal Sequence

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-- Install the 3033 as follows and carefully lift the cylinder head using the VAS 6100.

Fig 10: Identifying Lifting Tackle 3033 & VAS 6100

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Vibration damper side: -Item 3- on flywheel side: -Position 11-

NOTE:

The 3033 items marked 1 through 12 face toward the flywheel side.

Threaded spindles are set in length according to necessity.

-- Carefully lift the cylinder head off.

-- Stuff clean cloths into the cylinder bores so that no dirt or abrasive powder can get between the cylinder wall and piston.

-- Do not allow dirt or abrasive powder to get into coolant either.

-- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper below 100 grit).

Installing

-- Carefully remove metal particles, emery remains and the cloths.

If the piston for No. 1 cylinder is not at TDC:

-- Rotate the crankshaft using the vibration damper bolt in direction of engine rotation to TDC cylinder 1 marking -arrow-, have a second mechanic guide the camshaft roller chain by hand when doing this.

Fig 11: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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NOTE:

Only remove the new cylinder head gasket from its packing immediately before installing.

Handle the new gasket with extreme care. Damaging will lead to leaks.

-- Place a 2 mm thick bead of sealant D 176 501 as shown -arrows- onto the partition of the cylinder block/sealing flange.

Fig 12: Identifying Sealant Location For Cylinder Block/Sealing Flange

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-- Immediately place the new cylinder head gasket on. The text (replacement part number) must be visible.

-- Also fill some more sealant D 176 501 into both 3 mm bores in the cylinder head seal, which lie on the sealant bead.

-- Ensure the alignment pins in the cylinder block bore 12 and 20 are inserted and the cylinder head gasket is secured.

Fig 13: Identifying Cylinder Head Tightening Sequence

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-- Position the camshafts in the cylinder head to TDC No. 1 cylinder.

-- It must be possible to insert the T10068A into both camshaft grooves.

Fig 14: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

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-- Install the cylinder head, install new cylinder head bolts and hand tighten.

NOTE:

The longer cylinder head bolts must be inserted in the middle holes of the cylinder head.

-- Tighten the cylinder head bolts in the sequence shown, starting from the inside and working toward the outside, as follows:

Fig 15: Identifying Cylinder Head Tightening Sequence

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-- Pre-tighten all the bolts to 30 Nm.

-- Tighten all the bolts to 50 Nm.

-- Tighten all bolts 90° (1/4) additional turn, using a ratchet.

-- Afterwards, tighten all bolts again 90° (1/4) additional turn.

The rest of the assembly is basically a reverse of the removal sequence.

NOTE:

Ensure the O-ring for sealing the oil channel and the seal in the cover are installed.

-- Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

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

-- Fill the cooling system. Refer to DRAINING AND FILLING .

NOTE:

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