Cylinder Head

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. 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 = 700-1200 KG VAS 6100
Engine Bung Set VAS 6122
Drip Tray for VAS 6100 VAS 6208 or V.A.G 1306
Polydrive Bit and Drive Socket T10070
Cable Ties

Removing

NOTE:

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.

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 fluid and vacuum) and electrical wiring 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.

-- Lower the pressure in the high pressure side of the fuel system. Refer to HIGH SIDE FUEL PRESSURE, RELEASING .

-- Turn off the ignition and all electric consumers and remove the key.

-- 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.
Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

-- Open the cap on the coolant expansion tank.

-- Remove the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

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

-- Remove the right front wheel.

-- Remove the right front wheel housing liner. Refer to Removal and Installation .

-- Disconnect the charge air hose by lifting the clamp -1- and loosening the clamp -2-.

Fig 2: Identifying Charge Air Hose And Clamps

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-- Seal off the connection on the charge air cooler with a clean cloth.

-- Place the drip tray for VAS 6100 VAS 6208 or V.A.G 1306 under the engine.

NOTE:

Collect the leaking coolant in a clean container for disposal or reuse.

-- 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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-- Remove the charge air pipe by lifting the clamps -1 and 2-.

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

Fig 5: Identifying Turbocharger Electrical Connectors

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

Fig 6: Identifying Turbocharger Support And Bolts

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

Fig 7: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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

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

-- Remove the charge air pipe from the noise generator, if equipped. Refer to CHARGE AIR PIPE FROM NOISE GENERATOR .

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

Fig 8: Identifying Camshaft Adjustment Valve And Bolts

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-- Remove the ignition coils with output stages. Refer to IGNITION COIL WITH POWER OUTPUT STAGE . Lay the wiring harness to the side.

Fig 9: Identifying Crankcase Ventilation, Tightening Sequence

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

-- Remove the bolts -arrows-.

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

Fig 10: 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 system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the lines and catch any fuel coming out with a cloth.

Fig 11: Identifying Breather Line, Vacuum Line & Fuel Supply Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Ventilation line (press the circlip to release the line).
Vacuum line, if equipped (press the circlip to release the line).
Fuel supply line (pull the circlip upward to release the line).

-- Reposition the clamp -arrow- and remove the coolant hose from the expansion tank.

Fig 12: Identifying Coolant Line To Coolant Expansion Tank

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

Fig 13: 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 14: Identifying Vacuum Hoses

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-- Remove the bolts -1 though 3- and remove the heat shield and the coolant pipe.

Fig 15: Identifying Heat Shield Bolts

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Remove the bolt -2- from the heat shield using a 6 mm hex socket.

NOTE:

The hex socket -A- must be at least 5 cm -B- long. A socket that tapers to 6 mm at the tip is too wide.

Fig 16: Identifying 6mm Hex Socket -A-, 5cm Long -B-

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

Fig 17: Identifying Heat Shield Bolts

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

Fig 18: Identifying High Pressure Fuel Pump And Fuel Pressure Regulator Valve Electrical Harness Connector

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With Engine Code CBFA:

Fig 19: 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 by removing the bolts -arrows-.

Fig 20: Identifying Coolant Pipe And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for all Engine Codes:

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

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

Fig 21: Identifying EVAP Filter Vacuum Hose, Electrical Connectors And Electrical Cable

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-- Lay the wire -5- to the side.

-- Disconnect the EVAP canister vacuum hose -6-.

Fig 22: Identifying Vacuum Line And Electrical Connectors

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

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

-- Disconnect the coolant line from the intake manifold by the removing the bolts -arrows-.

Fig 23: Identifying Intake Manifold Coolant Line Bolts

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

Fig 24: Identifying Intake Manifold Bracket Mounting Nut And Bolt

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-- Remove the oil filter. Refer to OIL FILTER, OIL COOLER AND OIL PRESSURE SWITCH OVERVIEW .

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

Fig 25: Identifying Coolant Hoses

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

Fig 26: 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 a left hand threads.

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

Fig 27: Identifying Assembly Tool T10352 To Remove Control Valve

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

Fig 28: Identifying Bearing Bracket Bolts

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-- Using the counter hold Tool T10355, rotate the vibration damper to Top Dead Center (TDC) -arrow- :

Fig 29: 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 on the lower timing chain cover.
The marks -1- on the camshafts must point upward.

-- Carefully mark the position of the chain to the sprockets -A arrows- with a waterproof marker. Also mark the position of the chain to the guide rail -B arrows-.

Fig 30: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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These marks are necessary for reinstallation.

-- Remove the plug -arrow-.

Fig 31: 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.

-- Raise the locking wedge in the chain tensioner, insert the screwdriver into the chain tensioner bore in the -direction of arrow 1-.

Fig 32: 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 direction of engine rotation -2- and secure using 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 33: 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 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 plugs -arrows- counterclockwise -direction of the arrow- 90° (1/4) turn and remove.

Fig 34: 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 35: 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 n the camshaft with a wrench if necessary.

Make sure all necessary electrical wires are disconnected!

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

-- Install the engine Support T10014, and each of the two small and large washers, as shown in the illustration.

Fig 36: Identifying Engine Support -T10014-, Washers, Bolt And Engine Sling -2024 A-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

M8 washer, small.
M8 washer, large. The outer diameter of the washer must be larger than the hole in the bracket.
Bolt M8 x 30.

-- Connect the engine Sling 2024 A to the engine Support T10014 and to the front left lifting eye on the cylinder head.

-- Install the engine Sling 2024 A to the shop crane and gently lift the cylinder head.

Fig 37: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 tensioning and guide rail 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 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 the 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 the open valves.

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

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

NOTE:

Replace the bolts which are being tightened to a torque angle.

Replace sealing rings, seals and self-locking nuts.

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

Install only approved clamps for securing hose connections.

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

If an exchange cylinder head is installed, all contact surfaces between the bearing elements, roller rocker arms and cam running surfaces of camshafts must be oiled before installing the cylinder head cover.

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

-- Lift the cylinder head using the shop crane and position it above the cylinder block.

Fig 38: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

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

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

Fig 39: Identifying Cylinder Block Centering Pins
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Observe the cylinder head gasket location, identification: Replacement 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 hand tight.

NOTE:

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

Cylinder head bolt, tightening sequence and specification. Refer to Figure.

NOTE:

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

CAUTION:

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

-- Using the counter hold Tool T10355, rotate the vibration damper to TDC -arrow- :

Fig 40: 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 on the lower timing chain cover.

-- Install the timing chain on the intake camshaft.

Fig 41: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

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The marks must align.

-- Rotate 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.

-- Install the timing chain on the exhaust camshaft.

Fig 42: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marks on the drive chain and sprocket -A arrows- and the chain and guide rail -B arrows- must line up with each other.

-- Install the upper guide rail -3-.

Fig 43: 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 chain and guide rail -B arrows- do not align even though the engine is at TDC, the 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 44: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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

-- Fill the engine oil.

-- Check the oil level. Refer to OIL LEVEL, CHECKING .

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

-- Check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase any entries. Refer to "Guided Function" in the vehicle diagnostic tester.

NOTE:

If the DTC memory was erased, the readiness code must be generated again. Refer to "Guided Fault Finding" in the vehicle diagnostic tester.