Cylinder Head: Removing

WARNING: This page is about a different car, the 2013 Volkswagen Jetta and 2012 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

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: 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 [[Editorial:Pick one xref]]Removal and Installation .

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

Fig 2: Air Cooler Air Duct

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

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-- Remove the bolts -arrows-.

Fig 4: 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.

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

Fig 8: 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: 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

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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: Disconnecting 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: Fuel High Pressure Pump & 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: Coolant Pipe And Bolts

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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: 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: Bracket 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 & 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: Coolant Hoses

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

Fig 26: 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: 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 Markings -1- On Camshafts Aligned To Point Upward

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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: Identifying 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: 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: 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: 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 figure.

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

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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-

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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 tensioning and guide rail must not be damaged.

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