SM 4 PDF

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
15 – Cylinder head, valve gear

1 Chain drive
Assembly overview - timing chain covers ⇒ page 87 .
Removing and installing inlet camshaft control valve 1 - N205-
⇒ page 90 .
Removing and installing upper timing chain cover ⇒ page 90 .
Removing and installing lower timing chain cover (Passat, CC)
⇒ page 92 . wage
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Removing and installing
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⇒ page 105 .
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Assembly overview - camshaft timing chain ⇒ page 111 .
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Removing and installing camshaft timing chain ⇒ page 113 .
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Assembly overview – drive chain for balance shaft ⇒ page 125 .
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Removing and installing drive chain for balance shaft
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⇒ page 127 .
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Removing and installing balance shaft for inlet camshaft
⇒ page 127 .
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Removing and installing balance shaft for exhaust camshaft
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⇒ page 130 .
Check valve timing ⇒ page 133 .
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1.1 Assembly overview - timing chain covers

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1. Chain drive 87
4-cyl. injection engine (1.8 and 2.0agleengine,
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❑ Lubricate before as‐
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❑ 9 Nm
5 - Inlet camshaft control valve
1 - N205-
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❑ Removing and installing
⇒ page 90
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6 - Sealing ring
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❑ Lubricate before as‐
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⇒ page 90
⇒ page 89
9 - Seal
10 - O-ring
❑ Renew
❑ Lubricate before assembling.
11 - Dowel pins
❑ For centring cover
12 - Lower timing chain cover
❑ Tightening sequence for version with 15 bolts ⇒ page 89 .
❑ Tightening sequence for version with 8 bolts ⇒ page 89
Passat CC ⇒ page 92
Golf, Eos, Scirocco ⇒ page 98
Tiguan ⇒ page 105
13 - Bolt
❑ Renew
❑ Tightening sequence for version with 15 bolts ⇒ page 89 .
❑ Tightening sequence for version with 8 bolts ⇒ page 89
14 - Oil seal
❑ For vibration damper.
❑ Renewing ⇒ page 57
88 Rep. gr.15 - Cylinder head, valve gear

15 - Plugs
❑ Renew
Timing chain cover (top), tightening sequence

– Tighten bolts -1 to 5- in two stages in the sequence shown:
1- Tighten bolts by hand.
2- Tighten bolts to 9 Nm
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Lower timing chain cover - tightening sequence
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– Tighten bolts -1 to 15- in two stages in the sequence shown:
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– 1. Tighten bolts to 8 Nm.
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Lower timing chain cover – tightening sequence for version with

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– 2. Turn bolts 45° further. by c lksw
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1. Chain drive 89
1.2 Removing and installing camshaft con‐

trol valve 1 - N205-
– If fitted, remove charge air duct to sound generator
⇒ page 447 .
– Detach connector from inlet camshaft control valve 1 - N205-
-1-.
– Unscrew bolts -arrows- and remove inlet camshaft control
valve 1 - N205- .
Installing
• Specified torque ⇒ page 87
Install in reverse order of removal, observing the following.
– Lubricate seal and O-ring with engine oil.
1.3 Removing and installing upper timing

chain cover
Special tools and workshop equipment required
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♦ Torque wrench - V.A.G 1783-
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♦ Open-end spanner insert (10 mm) - V.A.G 1783/1-
Removing
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– Remove engine cover panel ⇒ page 139 .
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– Only vehicles with sound generator: Open catch -1-, unclip fuel
lines -2- and loosen bolt -3- on activated charcoal filter. Place s o
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charge air pipe to one side.
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Vehicles with activated charcoal filter in engine compartment:

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– Pull off breather line -1-, release activated charcoal filter -A-
and remove upwards -B-. Place activated charcoal filter to one
side.
All:
– Unscrew coolant pipe bolts -arrows- from intake manifold.

– Push coolant hoses to one side and secure on engine mount‐
ing using cable ties.
– Removing inlet camshaft control valve 1 - N205- .
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– Unscrew bolts -1…5- and remove upper timing chain cover.
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Unscrew lower bolts -3- and -5- using an ir se open-end spanner.
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– Lubricate gasket and O-ring with engine oil.

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– Position cover on engine, ensuring that gasket is correctly

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– Hand-tighten bolts -1 to 5- evenly in the sequence shown:

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– Further tighten bolts to 9 Nm. Use torque wrench - V.A.G 1783-

and open end spanner insert AF10 - V.A.G 1783/1- for bolts
-3- and -5-.
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– Install inlet camshaft control valve 1 - N205- ⇒ page 90 .

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1. Chain drive 91
– Tighten bolts -arrows- for guide tube.
Note
If the mounting holes don't align, check if the guide tube has been
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1.4 Removing and installing lower timing
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♦ Pin - T10060 A-
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♦ Counterhold tool - T10355-
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♦ Assembly tool - T10531-

♦ Bits - T10099-
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♦ Passat 2006▶: Rack - 10 - 222 A /1-

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♦ CC: Adapter - 10 - 222 A /8-
♦ Silicone sealant - D 174 003 M2-

Removing
– Remove vibration damper ⇒ page 50 .
– Drain engine oil.
– Support engine in installation position.
1. Chain drive 93
Passat 2006▶:
♦ Rack - 10 - 222 A /1-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-
CC:
♦ Adapter - 10 - 222 A /8-
♦ Hook - 10 - 222 A /10- agen
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♦ The shackle - 10 - 222 A /12- is needed so the engine is raised
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– Take up weight of engine with spindle.
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– Unscrew bolts -arrows- of engine/gearbox support on the en‐

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– Removing engine mounting ⇒ page 21 .
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– Raise engine approx. 50 mm and loosen upper engine support

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– Move electrical wiring harness clear -arrow-.

– Remove bolt -1- and take off tensioning device for poly V-belt
from bracket for ancillaries.
– Unscrew lower bolts for engine support using bits - T10099- .
– Remove engine support with bolts.

– Remove bolts -arrows- and pull guide tube for oil dipstick out
of timing chain cover.
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– Remove charge pressure solenoid valve - N75- from turbo‐
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– Remove turbocharger connection -1-.
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– Unscrew bolts -1 … 15-.
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Depending on version, the cover may be secured with only 8
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Caution
Risk of damaging lower timing chain cover. To prevent dam‐

aging the timing chain cover, apply tool only at the bolt holes.
1. Chain drive 95
– Lever off lower timing chain cover, starting at points

-1 and 2-.
Installing
♦ Specified torques ⇒ page 87
♦ Sealant: Silicone sealant - D 174 003 M2-
Note
♦ If the cover was bent during removal, it must be renewed.

♦ Note expiry date of silicone sealant.
♦ The cover must be installed within 5 minutes after applying the
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♦ Wear safety goggles.

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– Remove sealant residues from cylinder block with a flat scra‐

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– Mask oil seal on both sides with adhesive tape to make sure
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– Remove remaining sealant from cover, e.g. using rotating

plastic brush.
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– Clean sealing surfaces. They must be oil and grease free.

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Checking cover for distortion:

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– Fit cover using old bolts and tighten to 8 Nm.

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– Use feeler gauge to measure distance between cover and
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♦ Renew cover if distance exceeds 0.2 mm.

♦ It is not possible to measure distance between cover and sump
(top section); check visually to ensure that sealing surface is
even.

Installing cover:
– If necessary, unscrew flange nut - T10531/4- , and remove
turning over tool - T10531/3- .
– Check that both dowel pins for centring the cover -arrows- are
fitted.
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– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2
mm).
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1. Chain drive 97
Cover with 8 bolts

illustration.
Note

silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
– Install cover immediately and tighten bolts:

♦ Cover, version with 15 bolts ⇒ page 89
– Install vibration damper ⇒ page 50 .
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Further assembly is basically a reverse of the dismantling se‐
quence.
Note
After fitting cover, let sealant dry for approx. 30 minutes. Only then
fill with engine oil.
– Replenish engine oil and check oil level. olkswage es n
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1.5 Removing and installing lower timing chain cover (Golf, Eos, Scirocco) o tee
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Special tools and workshop

equipment required
♦ Support - 10 - 222 A-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-
♦ Pin - T10060 A-
♦ Bits - T10099-
♦ Golf: frame - 10 - 222 A /13-
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1. Chain drive 99
♦ Assembly tool - T10531- AG. Volkswagen AG d

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– Remove vibration damper ⇒ page 50 . cted agen
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Vehicles with sound generator:
– Remove charge air duct to sound generator ⇒ page 447 .
All:
– Fit support bracket - 10 - 222 A- with the following tool parts:
Golf:
♦ Adapter - 10 - 222 A /13- , qty. 2
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-

Eos, Scirocco:
♦ Rack - 10 - 222 A /1-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-
Note
♦ The rack feet - 10 - 222 A /1- must not be placed on the bolted
on sheet metal of the wings, or these might be damaged.
♦ The shackle - 10 - 222 A /12- is needed so the engine is raised
in its installation position and does not »fall back«.
All:
– Unscrew bolts -arrows- of engine/gearbox support on the en‐
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-1 and 2-.
Installing:
Note

silicone sealant.
♦ Renew bolts which must be tightened further to a torque angle.
♦ Renew seals, gaskets and self-locking nuts.
Caution
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1. Chain drive 103

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Note
– Replenish engine oil and check oil level.
1.6 Removing and installing bottom timing

chain cover (Tiguan)
♦ Support - 10-222A-
♦ Shackle - 10-222A/12-
♦ Adapter - 10-222A/16-
♦ Adapter - 10-222A/18-
♦ Adapter - 10-222A/22-
♦ Adapter - 10-222A/28-
1. Chain drive 105

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♦ Bits - T10099-
♦ Silicone sealant - D 174 003 M2-

Removing
– Remove motor cover panel ⇒ page 139 .
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– Fit support bracket - 10 - 222 A- as shown. The rear spindle is
not required. Attach hooks to support eyes on engine and
support engine and gearbox.
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1. Chain drive 107


– Remove bolt -1- and take off tensioning device for poly V-belt
– Unscrew lower bolts for engine support using bit - T10099- .
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charger -arrows-.
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-1 and 2-.
Installing:
Note

silicone sealant.
♦ Renew seals, gaskets and self-locking nuts.
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seal remains clean.
– Remove remaining sealant from cover, e.g. using rotating t to the co

plastic brush.
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– Clean sealing surfaces. They must be oil and grease free.

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1. Chain drive 109

Installing cover:
– Check that both dowel pins for centring the cover -arrows- are
fitted.
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mm).
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Note
– Replenish engine oil and check oil level.
1.7 Camshaft timing chain - exploded view
1. Chain drive 111

1 - Bolt
❑ 9 Nm
2 - Chain tensioner
❑ Is spring-loaded
❑ Depending on version,
secure with locking pin -
T40011- or locking tool -
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❑ Remove with assembly
tool - T10352-
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❑ Engine codes CCZA,
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11 - Camshaft case
12 - Camshaft timing chain
❑ Before removing, mark running direction with paint
❑ Removing and installing ⇒ page 113
13 - Guide rail for camshaft timing chain
14 - Guide pin
❑ 20 Nm
15 - Chain sprocket
❑ Crankshaft
❑ Fitting position ⇒ page 113

Crankshaft chain sprocket - installation position

• The two sections -arrows- must be aligned.
1.8 Removing and installing camshaft timing chain

equipment required
♦ Engine codes CCZA,
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CCZB, CCZC, CCZD,
CDAA, CDAB: assembly
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1. Chain drive 113

Components of assembly tool - T10531- :

♦ Support - T10531/1-
♦ Clamping pin - T10531/2-
♦ Turning over tool - T10531/3-
♦ Collar nut - T10531/4-
cardiagn.com
Removing:
– Remove timing chain cover (top) ⇒ page 90 .
– Turn vibration damper to “TDC” position -arrow- using coun‐
terhold - T10355- .
• Notch on vibration damper must align with arrow marking on
cover for timing chains (bottom).
• The markings -1- on the camshafts must face upwards.
– Remove lower timing chain cover:
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The control valve has a left-hand thread.

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– Remove bolts -arrows- and detach bearing saddle.
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– Press oil pump chain tensioner in direction of -arrow- and lock ot p
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Depending on version, either of 2 different chain tensioners may

be installed. Variant 1:
– Screw in lever - T40243- -arrows-.
– Raise locking element of chain tensioner -arrow 1-. To do this,
grind the tip of the locking pin - T40011- to a point. A screw‐
driver with a blade width of approx. 1.5 mm can also be used.
Caution
Avoid damage to chain tensioner! Proceed with great care.
– Slowly push valve lever - T40243- in -direction of arrow 2- and

hold it in that position.
1. Chain drive 115

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– Press together retaining ring -1- of chain tensioner and hold it
n
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– Remove lever - T40243- .

– Bolt camshaft clamp - T40271/2- to cylinder head and insert it

in direction of arrow -2- between teeth of sprocket. If necessary
turn inlet camshaft slightly using spanner -1-.
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– Bolt camshaft clamp - T40271/1- to cylinder head. Brace cam‐
cardiagn.com
shaft clockwise -arrow- using open-end spanner.
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– Unscrew bolt -A- and remove tensioning rail while continuing
to brace camshaft.
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– Insert camshaft clamp - T40271/1- between teeth of sprocket

-2-. If necessary, turn exhaust camshaft clockwise -1- until the
camshaft clamp can be inserted. The camshaft timing chain
between the sprockets must be »loose«.
1. Chain drive 117

– Unscrew bolts -A- and remove guide rail for camshaft timing
chain.
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– Remove camshaft timing ised chain from camshaft sprockets andarant
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– Remove chain tensioner -1- for balance shaft drive chain.

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– Unscrew bolts -1-. Remove tensioning rail -2- and guide rails Prote
cted AG.
agen
-3- and -4-.

– Loosen tensioning bolt -A-, and unscrew cotter pin -B-.

– Remove triple chain sprocket. To do this, remove drive chain
for oil pump.
– Remove camshaft timing chain.
AG. Volkswagen AG d
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Installing s aut ra
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• Specified torques ⇒ page 111 .
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– Check if crankshaft is positioned at TDC. The flat section on
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– Mark tooth -1- of triple chain sprocket which is aligned with
ss
marking -2- using a permanent felt tip marker.
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– Turn idler gear and balance shaft so that markings -arrow- are
aligned as shown in illustration. Do not loosen bolt -1-. The
markings on idler gear and balance shaft are difficult to see
and align only after every 7th turn.
1. Chain drive 119

– Fit drive chain for balance shafts. Position chain links with col‐
oured markings -arrows- at markings on chain sprockets.
AG. Volkswagen AG d
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– Install guide rail -1-, andd by tighten bolts -arrows-.
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markings -arrows- properly aligned.
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– Fit drive chain for oil pump onto triple chain sprocket.
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– Swing triple sprocket towards engine (-direction of arrow-),
and fit it onto crankshaft. The markings -arrows- must align.

I - Screw clamping pin - T10531/2- into crankshaft, and tighten it

by hand.
II - Fit turning over tool - T10531/3- . Screw on flange nut -
T10531/4- by hand. Slightly move turning over tool back and forth
with a 32 mm open-end spanner. While doing so, retighten flange
nut until the chain sprocket is securely seated on the crankshaft
splines. Now, tighten tensioning bolt -A-.
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marking -arrow- at marking of triple sprocket. Install tensioning
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– Install chain tensioner -1-.

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– Make sure that adjustment has been carried out correctly:

chain links with coloured markings -arrows- must be posi‐
tioned at markings on chain sprockets.
1. Chain drive 121

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– Fit camshaft timing chain on inlet scamshaft, exhaust camshaft
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-arrows- at the markings on chain sprockets.
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– Fit guide rail for camshaft timing chain and tighten bolts -A-.
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Have a second mechanic hold the exhaust camshaft. Prote AG.
– Slowly turn exhaust camshaft in direction of arrow -1- until

camshaft clamp - T40271/1- can be withdrawn from sprocket
teeth.
– Carefully relieve load on camshaft until camshaft timing chain
lies against upper guide rail. Hold camshaft in this position.
Caution
Before installing the tensioning plate it is essential to check

whether the coloured chain link is still aligned with the crank‐
shaft marking.

– Continue to hold camshaft and install tensioning rail for cam‐

shaft timing chain. Tighten bolt -A-.
– Remove camshaft clamp - T40271/1- .
– Slide camshaft clamp - T40271/2- out of sprocket teeth -2-, if
cardiagn.com
necessary turning inlet camshaft slightly using spanner -1-.
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1. Chain drive 123

– Check position of coloured chain links relative to markings.
– Install chain tensioner -2-. The retaining clip -arrow- must be
cardiagn.com
seated in recess in top section of sump. Tighten bolt -1-, and
remove locking pin - T40011- .
– Screw in and tighten bolts -arrows-.

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– Fit bearing saddle carefully. Do not cant bearing saddle! Screw

in bolts -arrows- and tighten by hand.
– Tighten bolts -arrows- for bearing saddle ⇒ page 111 .
rrectness of i
– Install control valve ⇒ Item 6 (page 112) .

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Rep. gr.15 - Cylinder head, valve gear Prote AG.
– Using a 32 mm open-jaw spanner on assembly tool -

T10531/3- , rotate crankshaft 2 full turns in direction of engine
rotation. At “TDC position” the flat section -1- faces upwards.
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Due to the ratio, the coloured schain
sa links do not align with the c
markings any more after the engine has been turned.
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1.9 Assembly overview - drive chain for balance shaft
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1 - Bolt
❑ 9 Nm
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2 - Balancer shaft
ss
❑ Renew after removing
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❑ Exhaust side
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❑ Lubricate bearing with
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engine oil
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❑ Removing ⇒ page 130
thi
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3 - Tube for balancer shaft

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❑ Fitting position
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⇒ page 126
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4 - Chain tensioner
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❑ 85 Nm
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5 - Cylinder block
6 - Balancer shaft
❑ Renew after removing
❑ Inlet side
❑ Lubricate bearing with
engine oil
❑ Removing ⇒ page 127
7 - O-ring
❑ Lubricate with engine oil
8 - Locating pin
❑ Fitting position
⇒ page 126
9 - Intermediate shaft sprocket
❑ For balancer shaft.
❑ If the securing bolt has
been loosened, the intermediate shaft sprocket must be renewed.
10 - Bolt
❑ 9 Nm
11 - Washer
12 - Securing bolt
❑ If the securing bolt has been loosened, the intermediate shaft sprocket must be renewed.
❑ Tightening sequence ⇒ page 127
1. Chain drive 125

13 - Slide rail
❑ For drive chain.
14 - Guide pin
❑ 20 Nm
15 - Tensioning rail
16 - Guide pin
❑ 20 Nm
17 - Drive chain for balance shafts
18 - Chain sprocket
❑ Fitting position ⇒ page 113
19 - Slide rail
20 - Guide pin
❑ 20 Nm
cardiagn.com
AG. Volkswagen AG d
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Tube for balancer shaft
Vol - installation position
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• Lug ise balance
on tubehorfor shaft must engage in slot -arrow-.
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Bearing mounting - installation position

rrectne
• Renew O-ring -1- and lubricate with oil

s
• Dowel pin -arrow- for bearing mounting must engage in bore

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• Lubricate bearing mounting.

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Chain sprocket - tightening sequence
Caution
The intermediate shaft sprocket must be replaced. Otherwise

no tooth backlash is set - engine damage. The new intermedi‐
ate shaft sprocket is coated with a solid film lubricant that wears
off after a short period and thus automatically sets the tooth
backlash.
– Tighten bolt as follows:

1. Pre-tighten to 10 Nm using torque wrench.
2. Turn sprocket.
Chain sprocket must be without play; otherwise loosen bolt and
tighten again.
3. Tighten to 30 Nm using torque wrench.
4. Use fixed wrench to turn 90° further.
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1.10 Removing wand agen installing drive
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The procedureaut“Removing
ho and installing drive chain for balance
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shaft” is partssof the procedure “Removing and installing camshaftc
timing chain” ⇒ page 113 .
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1.11 Removing and installing inlet side bal‐

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♦ Puller - T10394-
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priv
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♦ Puller - T10055-
f
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1. Chain drive 127

Note
The balance shaft must always be renewed after removing.
Removing: AG. Volkswagen AG d

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– Remove toothed belt for coolant pump ⇒ page 247 . by Vo gu
ara
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– Remove timing chain cover (top) ⇒ page 90 . uthor eo
a ra
s c
– Remove lower timing chain cover: s
ce
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Tiguan ⇒ page 105
, is n
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– Remove camshaft timing chain and drive chain for balance
spec
shaft ⇒ page 113 .
es, in part or in w
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– Remove intermediate gear -1-.
rrectness of i
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– Unscrew bolt -2- for inlet camshaft balance shaft and pull out Cop py
t. rig
balance shaft. opyri
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If balance shaft cannot be pulled out by hand, use puller -
by lksw
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T10394- :
AG.
– Insert shell half - T10394/1- from puller - T10394- and turns

upwards in direction of arrow.

– Insert puller - T10394- and push locking collar in

-direction of arrow-.
– Screw puller - T10055- into puller - T10394- and force out bal‐
ance shaft in -direction of arrow-.
Installing
Note
Due to the small amount of play between the balance shaft and
cardiagn.com
cylinder block, the balance shaft may need to be installed chilled.
Check whether the balance shaft can be fitted into the cylinder
block without exerting force. If this is not the case, the balance
shaft must be chilled before installing.

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– Place new balance shaft in freezer compartment for 30 mi‐ Vol
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– Lubricate balancer shaft bearing with engine oil.auth ra
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– Install new balancer shaft for inlet camshaft and tighten bolt
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– Renew O-ring -1- and lubricate with engine oil.

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– Lubricate bearing mounting with engine oil and insert

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-arrow-; bearing mounting must engage in bore in cylinder

n
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block.
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Caution
for
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The intermediate shaft sprocket must be replaced. Otherwise
C py
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no tooth backlash is set - engine damage. The new intermedi‐
ht
pyri by
ate shaft sprocket is coated with a solid film lubricant that wears
co Vo
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off after a short period and thus automatically sets the tooth Prote AG.
backlash.
1. Chain drive 129

– Mark faces of gear teeth of idler gear with paint -arrows-.

– Insert intermediate gear; marking on balance shaft must be
positioned between markings on faces of gear teeth.
– Tighten bolt for sprocket -1-: tightening sequence

⇒ page 127 .
– Check markings on intermediate shaft sprocket/balancer shaft
-arrow-.
Note
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AG. Volkswagen AG d
Due to the ratio, the markings align only after every 7th turn. lksw
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– Install drive chain for balance shaft and camshaft timinghchain
oris nte
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⇒ page 119 . s aut ra
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The remaining installation steps are carried out in the reverse se‐
ce
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quence. Note the following:
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– Renew oil seal for coolant pump drive ⇒ page 249 .
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1.12 Removing and installing exhaust side
h re
hole
spec
balance shaft
es, in part or in w
t to the co
♦ Puller - T10394-
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♦ Puller - T10055-
AG. Volkswagen AG d
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Note
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The balance shaft must always be renewed after removing.
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Removing:
nform
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– Remove lower timing chain cover:
n
c
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or
his
ate
do
priv

um
for
en
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t.
Tiguan ⇒ page 105
yi Co
Cop py
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– Remove camshaft timing chain and drive chain for balance
gh ht
pyri by
shaft ⇒ page 113 .
co Vo
by lksw
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– Unscrew bolt -1- and pull out balance shaft.
If balance shaft cannot be pulled out by hand, use puller -
T10394- :
– Insert shell half -T10394/1- from puller - T10394- .
1. Chain drive 131

– Insert puller - T10394- and push locking collar in

-direction of arrow-.
AG. Volkswagen AG d
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– Screw puller - T10055- into puller - T10394- and force out bal‐ d by Vo gu
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Installing: ss a c
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Note
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Due to the small amount of play between the balance shaft and
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cylinder block, the balance shaft may need to be installed chilled.
h re
hole
Check whether the balance shaft can be fitted into the cylinder
spec
block without exerting force. If this is not the case, the balance
es, in part or in w
shaft must be chilled before installing.
t to the co
rrectness of i
– Check installation position of tube for balancer shaft -arrow-.
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The lug -arrow- must be on top. It functions as an anti-twist device.
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To get the tube into installation position, it must be squeezed to‐
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gether slightly. Insert 2-hole pin wrench - 3212- in front bores of
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tube and press together. Then insert pipe with 2-hole pin wrench
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- 3212- .
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– Place new balance shaft in freezer compartment for 30 mi‐ yri
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nutes or spray with commercially available chilling spray.
c by lksw
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– Lubricate balancer shaft bearing with engine oil.
– Install balance shaft for exhaust camshaft.
– Before tightening bolt -1-, check that balance shaft rests flat
against crankcase.
Note
If the balancer shaft does not rest flat, the pipe for balancer shaft
must be inserted again.
– Install drive chain for balance shaft and camshaft timing chain
⇒ page 119 .
quence.

1.13 Checking valve timing

♦ Dial gauge - VAS 6079-
lkswage es n
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♦ Dial gauge adapter
tho - T10170 A- tee
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au ac
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ility
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es, in part or in w
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♦ Depth gauge
nf
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– Remove right wheel and right wheel housing liner.

rm
m
atio
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– Using 24 mm socket, turn crankshaft via vibration damper in

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c
normal direction of rotation until markings -arrows- are almost

or
thi
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at top.
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– Remove spark plug from cylinder 1.

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1. Chain drive 133

– Screw dial gauge adapter - T10170/A- into spark plug hole to

stop.
– Insert dial gauge - VAS 6079- with extension - T10170A/1- as
far as it will go and secure in place with self-locking nut
-arrow-.
– Slowly turn crankshaft in engine DOR to maximum needle de‐
flection. Once maximum needle deflection is reached (reverse
point of needle), piston is at »TDC«.
Note
If the crankshaft has been turned beyond »TDC« turn engine an‐
other two revolutions in direction of engine rotation. Do not turn
engine in opposite direction of engine rotation!
– Measure distance from left outer edge of web -A- to marking

-B- on inlet camshaft.
• Specification: 61 to 64 mm.
cardiagn.com
– If the specified value is achieved, measure the distance be‐
tween the marking on the inlet camshaft -B- and the marking
on the exhaust camshaft -C-.
• Specification: 124 to 126 mm agen
AG. Volkswagen AG d
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Note uthor eo
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An offset of one tooth results in a deviation of approx. 6 mm from
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the specified value. If an offset is found, the timing chain must be

an
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re-fitted.
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ility
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2 Cylinder head
Assembly overview - cylinder head ⇒ page 135 .
Removing and installing engine cover panel ⇒ page 139 .
Removing and installing cylinder head ⇒ page 140 .
Compression test ⇒ page 176 .
Removing and installing vacuum pumpo⇒
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2.1 Assembly overview - cylinder head
e ran
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♦ If the cylinder head bolts have multi-point sockets and a shoul‐
pe
ility
der, the camshafts must be removed before the cylinder head
ot
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bolts are unscrewed.
h re
hole
♦ When assembling, renew self-locking nuts, bolts that are tight‐
spec
ened by turning further angle, as well as seals and gaskets.
es, in part or in w
t to the co
cardiagn.com
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
rrectness of i
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1 - Cylinder head gasket

❑ Renew
nform
ercia
❑ Observe installation po‐

m
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sition: Part number to
com
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cylinder head
n in
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thi
2 - Bolt
s
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❑ 25 Nm
um
fo
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t.
3 - Transportation shackle
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4 - Bolt
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⇒ page 138
Prote AG.
5 - Cylinder head
⇒ page 140
❑ Check for distortion
⇒ page 138 .
❑ Renew oil non-return
valve in cylinder head
⇒ page 138
6 - Cylinder head bolt
❑ Renew
❑ Note sequence when
loosening ⇒ page 137 .
❑ Note correct sequence
when tightening
⇒ page 138 .
7 - O-ring
❑ Renew
8 - Plugs
❑ 5 Nm
2. Cylinder head 135

❑ With ball head for engine cover panel
9 - Cap
❑ With seal
10 - O-ring
❑ Renew
11 - Plugs
12 - Holder
13 - Bolt
❑ 9 Nm
14 - Heat shield
15 - Bolt
❑ 20 Nm
16 - Bolt
❑ 20 Nm
17 - To intake hose/turbocharger
cardiagn.com
18 - Breather pipe
19 - O-ring
❑ No replacement part.
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20 - Seal wage
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21 - Motor cover aut ra
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22 - Bolt
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❑ Self-tapping
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23 - Crankcase ventilation
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❑ Note correct sequence when tightening ⇒ page 137 .

ole,
spec
24 - To intake manifold
t to the co
25 - Seal
rrectne
26 - Seal
s
❑ Renew
s o
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27 - Vacuum pump
inform
mer

atio
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28 - Securing bolts for vacuum pump

o
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❑ Engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA: 9 Nm

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❑ Engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB: 8 Nm + additional 180° turn
i
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Renew after removal

t.
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29 - 9 Nm
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rig by
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❑ Only engine code CBFA by c lksw
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Prote AG.
30 - Secondary air inlet valve - N112-
❑ Only engine code CBFA
31 - Seal
❑ Only engine code CBFA

❑ Renew
32 - Retaining plate
33 - Bolt
❑ 9 Nm
34 - Union
❑ Engine code CBFA: before removal, secondary air inlet valve - N112- must be removed ⇒ page 550
35 - O-ring
❑ Renew
❑ Lubricate with coolant
36 - Bolt AG. Volkswagen AG d
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❑ 25 Nm olksw not
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37 - Transportation
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38 - Bolt ss c
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❑ 9 Nm
nl
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39 - Hall sender - G40-
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40 - Partition
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Crankcase breather system - tightening torque
es, in part or in w
t to the co
– Tighten bolts for crankcase breather in the sequence
-1 … 10- to 11 Nm.
rrectness of i
l purpos
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Loosening cylinder head bolts

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by lksw
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Prote AG.
♦ If a cylinder head cover without sealing plugs for the cylinder
head bolts -5- is installed, the camshafts must be removed.

– Slacken cylinder head bolts in the sequence -1 … 5-.

Cylinder head - tightening sequence, camshaft installed

– Tighten cylinder head bolts in the sequence -1 … 5- as follows:
1- Tighten initially to 40 Nm using torque wrench
2- Turn 90° further using rigid wrench
– Then tighten bolts -arrows-.
1- Pre-tighten bolts to 8 Nm
AG. Volkswagen AG d
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2- Turn bolts 90° further using
Vol rigid wrench
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Cylinder head - tightening sequence, camshaft removed au ra
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– Tighten cylinder head bolts in the sequence -1 … 10- as fol‐
pt
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lows:
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1- Tighten initially to 40 Nm using torque wrench
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es, in part or in w
t to the co
– Then tighten bolts -arrows-.
1- Pre-tighten bolts to 8 Nm
rrectness of i
2- Turn bolts 90° further using rigid wrench
l purpos
Checking cylinder head for distortion

nf
ercia
– Use straight edge 500 mm - VAS 6075- and feeler gauge to

or
measure cylinder head for distortion at several points.

m
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♦ Max. permissible distortion: 0.05 mm.

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2.2 Renewing oil non-return valve in cylin‐

der head
♦ Hooks e.g. assembly tool - T10118-

AG. Volkswagen AG d
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Removing olksw not
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– Remove cylinder head ⇒ page 140 . horis nte
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aut ra
– Pull out oil non-return valve -arrow- with a suitables hook, e.g.
s c
assembly tool - T10118- .
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Installing
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– Clean oil channels.
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– Moisten seal for new oil non-return valve with clean engine oil.
h re
hole
spec
– Insert oil non-return valve by hand into cylinder head to stop.
es, in part or in w
t to the co
– Install cylinder head ⇒ page 140 .
2.3 Removing and installing engine cover
rrectness of i
l purpos
Removing
– Pull engine cover panel off upwards at securing points
nf
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-arrows-.
orm
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Installing
om
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Vo
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by c lksw
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Prote AG.
– When fitting, make sure that rubber buffers are correctly in‐
serted in mountings.
– Press engine cover panel back carefully into its retainers.
– To prevent damage, do not strike engine cover panel with the
fist or a tool.

AG. Volkswagen AG d
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olksw not
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CC 2010 ➤ thor , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤tee, oPassat 2006 ➤ , ...
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4-cyl. injection
ss
a engine (1.8 and 2.0 l engine, chain drive) -aEdition c 02.2017
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un
pt
2.4 Removing and installing cylinder head
an
d
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ab
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ility
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Note
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ If cylinder head bolts with a multipoint socket head and shoul‐
rrectness of i
der are used for installation, the cylinder head bolts must be
inserted before the camshafts are installed.
l purpos
♦ If a cylinder head cover without sealing plugs for the cylinder

head bolts -5- is or is going to be installed, the camshafts must
nform
ercia
be removed.
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Checking guide rail version:

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thi
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Note
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C
Depending on the respective repair work to be carried out and on
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the version of the guide rail, different procedures apply. Please
p by
co Vo
by lksw
check which guide rail is installed before starting work. Prote
cted AG.
agen

– Check guide rail -1- in area indicated by -arrow-.
A - Long guide rail
B - Short guide rail
Removing cylinder head, if a »short« guide rail is installed and the
camshaft timing chain shall remain installed:
Procedure
⇒ “2.4.1 Removing and installing cylinder head”, page 140 .
Removing cylinder head, if a »short« guide rail is installed and the
camshaft timing chain is to be removed as well:
Procedure
⇒ “2.4.2 Removing and installing cylinder head and camshaft
timing chain”, page 163 .
Removing cylinder head, if a »long« guide rail is installed:
Procedure
⇒ “2.4.2 Removing and installing cylinder head and camshaft
timing chain”, page 163 .
2.4.1 Removing and installing cylinder head


equipment required
CCZB, CCZC, CCZD,
tool - T10352/1-
♦ Locking pin - T40011-
AG. Volkswagen AG d
♦ Camshaft clamp - T40271- agen oes
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♦ Torque wrench - V.A.G

1331-
1332-
♦ Workshop hoist - VAS
6100-
♦ Engine plug set - VAS
6122-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Polydrive cylinder head
bolts: Special wrench, long
reach - T10070-
♦ Cylinder head bolts with
multi-point socket: Multi-
point socket 12 mm
cardiagn.com
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♦ Lifting tackle - 2024 A-
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♦ Holder - T10014-
♦ Puller - T40039-
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Removing:
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Note
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♦ Fit cable ties in the original positions when installing.

♦ Always seal open channels of the intake and exhaust systems
rrectness of i
with suitable plugs. For example, those from engine bung set
l purpos
- VAS 6122- .
nform
ercia
– Pull off engine cover panel ⇒ page 139 .

m
– Remove air filter housing ⇒ page 459 .

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– Release hose clip -2-.

– Unscrew bolt -4-.
– Disconnect electrical connector -arrow- and move electrical
wires clear.
WARNING
Danger of scalding due to steam and hot coolant.

On a warm engine, the cooling system is under high pressure.
Reduce excess pressure by covering the cap of the coolant
expansion tank with cloths and opening it carefully.
– Open filler cap on expansion tank.

– Remove front exhaust pipe with catalytic converter:
Passat, CC ⇒ page 517
cardiagn.com
Tiguan ⇒ page 543
wage es n
– Remove front right wheel. yV
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– Remove noise insulation
thoris
⇒ General body repairs, exterior; tee
or
Rep. gr. 50 ; Noise
au insulation . ac
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– Remove right wheel housing liner ⇒ General body repairs,

nl
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exterior; Rep. gr. 66 ; Wheel housing liner .

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itte
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– Drain coolant ⇒ page 235 .

ility
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– Remove charge air hose -A-.

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es, in part or in w
t to the co
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c
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– Remove bolt -1- and take out air pipe downwards.

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– Remove bolts -arrows-.

– Remove air pipe (lift clips -items 1 and 2-).
– Separate electrical wiring connections -1 and 2- and place

electrical wiring to one side -arrows-.
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Vehicles with seat heating:
h re
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spec
– Unscrew bolts -1 and 2- and move coolant pipes to the left.
t to the co
Vehicles with all-wheel drive:
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
rrectness o
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All vehicles:
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– Remove bolts -1 and 2- and detach support for turbocharger.

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– Remove banjo bolt -2-
ss and move coolant pipe clear to one
ce
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side.
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Vehicles with front-wheel drive:
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– Remove bolts -1- on oil return line.
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– Remove bolts of oil return line at crankcase.
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All vehicles:
– Remove bolt -3- on oil supply line.
rrectness of i
– Only vehicles with sound generator: Remove charge air duct
l purpos
to sound generator.
– Pull connector -1- off camshaft control valve 1 - N205- .
nform
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– Detach connectors from ignition coils and place wiring harness

to one side.
– Remove ignition coils using puller - T40039- .
Engine codes BZB, CAWA, CAWB, CGYA, CDAA:

– Unscrew bolt -arrow- for air pipe.
– Remove air pipe, loosening hose clip -1- to do so.
– Press release tabs -2-, and pull crankcase breather off air
hose.

– Disconnect crankcase breather hose -1-.

– Remove bolts -arrows- and remove crankcase breather.
AG. Volkswagen AG d
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Engine codes CBFA, CCTA, CCTB:
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nform
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c
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ate
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– Loosen hose clip -1- and remove air pipe together with crank‐
p
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case breather.
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All:
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
– Detach lines -1 to 3- from the fuel transfer point.

1) Breather hose
2) Vacuum line (only CBFA, CCTA, CCTB)
3) Fuel supply line

– Disconnect coolant line to coolant expansion tank -arrow-.
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– Remove coolant hoses -arrows- from coolant pipe.
spec
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– Unbolt earth cable -3- and loosen bolt -4-.
t to the co
rrectness of i
l purpos
cardiagn.com
nform
mercia
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com
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r
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– Pull off vacuum hoses -arrows-.
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– Unscrew bolts -1…3- and remove heat shield together with

coolant pipe.
– Unscrew oil supply line -4- from turbocharger.

Note
Unscrew bolt -2- from heat shield using a 6 mm hex key -A-. The
hexagon faces must be at least 5 cm long -B-. A socket which
tapers to 6 mm at the tip is too thick.
AG. Volkswagen AG d
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– Pull off electrical connector -2- from fuel pressure regulating
s
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valve - N276- .
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Engine code CBFA:

nform
ercia
– Pull connector -A- and hose -B- from secondary air inlet valve
- N112- .
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– Loosen coolant pipe by unscrewing bolts -arrows-.

AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ e,dGolf by 2009 ➤ , Passat 2006 ➤ , ... guara
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4-cyl. injection engine (1.8 and 2.0 l engine,
tho chain drive) - Edition 02.2017 eo
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All:
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– Pull coolant hose from union on side of cylinder head.
itte
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– Separate electrical connectors -1 to 4-.
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– Place electrical cable -5- to one side.
h re
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spec
– Pull off vacuum line -6- leading to activated charcoal filter.
es, in part or in w
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rrectness of i
l purpos
Golf, Scirocco:
nform
ercia
m
at
and remove upwards -B-.
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cardiagn.com
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All:
– Separate electrical connectors -1- and pull out connectors
from retainer.
– Unscrew bolts -arrows- and detach coolant pipes from intake

manifold.

AG. Volkswagen AG d
agen
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oes ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
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V
d by 4-cyl. injection engine (1.8
gu and 2.0 l engine, chain drive) - Edition 02.2017
ara
rise nte
tho eo
– Remove
ss a intake manifold support (remove securing nut -1-
u r a and
c
bolt -2-).
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– Removing oil filter
itte
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– Disconnect coolant hoses -arrows- and move clear.
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valve 1 - N205- .
Caution


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– Turn vibration damper
s au to “TDC” position -arrow- using coun‐ ra
c
terhold - T10355-s .
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– Mark positions of sprocket markings -1- on camshaft timing

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chain and cylinder head -arrows- using a permanent felt tip

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– Also mark alignment of camshaft timing chain -2- relative to
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guide rail of camshaft timing chain using a permanent felt tip
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agen
– Remove sealing plug -arrow-.

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Depending on version, either of two different chain tensioners
may be installed. Version 1:
ss o
cial p
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mer
atio
Note
om
n
c
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♦ If it is not possible to insert the lever - T40243- , the distance

t
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cover is too small. It is then necessary to remove the lower
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♦ Passat, CC ⇒ page 92
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♦ Golf, Eos, Scirocco ⇒ page 98
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♦ Tiguan ⇒ page 105

Caution


AG. Volkswagen AG d
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– Screw in lever - T40243- -arrows-. aut ra
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cover.
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– Press together securing clip -arrow- of chain tensioner. Then,
o
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slowly push lever - T40243- in -direction of arrow- and hold it
inform
in that position.
mer
atio
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Continued for all:

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– Bolt camshaft clamp - T40271/2- to cylinder head and insert it

in direction of arrow -2- between teeth of sprocket. If necessary
turn inlet camshaft in direction of arrow -1- using spanner.
– Bolt camshaft clamp - T40271/1- to cylinder head. Counter‐
cardiagn.com
hold camshaft clockwise -arrow- using open-end spanner.
– Remove bolt -A- and take out tensioning rail downwards. In
the process, continue to counterhold the camshaft. en AG. V
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– Turn exhaust camshaft clockwise -1- until camshaft clamp -
ss
T40271/1- can be inserted into sprocket splines -2-.

o
cial p
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mer
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Cop py
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Prote AG.

– Use screwdriver to release fastener and press off top guide

rail towards front -1-. Mark position of sprockets -arrow- rela‐
tive to camshaft clamp.
– Remove camshaft timing chain from camshaft sprockets.
Caution
Avoid damage to valves and piston crowns.

♦ Do not turn the crankshaft after the camshaft timing chain
has been removed from the cylinder head.
AG. Volkswagen AG d
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– If a cylinder head cover without sealing plugs for the cylinder d by V gu
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head bolts -5- is installed, remove the camshafts orise nte
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⇒ page 183 . aut
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– If a cylinder head cover with sealing plugs for all cylinder head
bolts is installed, turn sealing plugs -arrows- anti-clockwise in
l purpos
direction of -arrow- by 90° and remove.

– Unscrew ball head -1 … 2-.
nf
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– Remove filler cap.
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Multi-point socket head bolt with shoulder:
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– Remove camshafts ⇒ page 183 .
– Unscrew and remove cylinder head bolts in the sequence
-1 to 10-.

Polydrive bolts: . Volkswagen AG

gen AG does
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– Unscrew bolts y V -arrows-.
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– Unscrew horis
cylinder head bolts using polydrive bit and e osocket -
aut
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Note
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♦ Make sure all hoses/pipes and wiring are removed.
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♦ Ensure tensioning rail and guide rail are not damaged when
hole
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lifting off cylinder head.
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t to the co
– Remove cylinder head.
– Place cylinder head onto soft surface (foam plastic).
rrectness of i
Install cylinder head ⇒ page 160 .
l purpos
If the camshafts are renewed, the markings which you applied
nform
ercia
earlier must be transferred. To do so, proceed as follows:

m
– Mark alignment of camshaft sprockets relative to camshaft
at
cardiagn.com
om
io
clamp - T40271/1- and camshaft clamp - T40271/2- on re‐
n
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moved cylinder head -arrow-.

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whether the markings have been correctly transferred.
op Vo
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Prote AG.

-B- on inlet camshaft and record figure.
– Measure distance from marking on inlet camshaft -B- to mark‐

ing on exhaust camshaft -C- and record figure.

– Turn inlet camshaft in direction of arrow -1- using spanner,

slide camshaft clamp - T40271/2- from between teeth of
sprocket -2-and move camshaft into rest position.
AG. Volkswagen AG d
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– Turn exhaust camshaft in direction of arrow -1- using spanner,

nl
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du
cardiagn.com
slide camshaft clamp - T40271/1- from between teeth of
an
itte
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sprocket -2-and move camshaft into rest position.
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markings applied when removing. t. Cop py
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4-cyl. injection engine
wage (1.8 and 2.0 l engine,
e chain drive) - Edition 02.2017
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Vol t gu
by ara
– Bolt camshaft clamp - T40271/2- ris to cylinder
ed
head to be instal‐ nte
led. autho eo
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– Turn inlet camshaft in direction of arrow -1- until marking -3-
ce
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nl
aligns with camshaft clamp - T40271/2- .
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– Insert camshaft clamp - T40271/2- into teeth of sprocket -2-.
erm
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ility
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t to the co
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nform
mercia
at
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ion
c
in t
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– Compare distance from left outer edge of web -A- to marking

o
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te
cardiagn.com
-B- with figure recorded earlier.
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for
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pyri by
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– Bolt camshaft clamp - T40271/1- to cylinder head.

– Turn exhaust camshaft in direction of arrow -1- until marking
-3- aligns with camshaft clamp - T40271/1- .

– Compare distance from marking on inlet camshaft -B- to mark‐

ing on exhaust camshaft -C- with figure recorded earlier.
Installing cylinder head:
Caution
Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Avoid damage to cylinder block. . Volkswage
AG n AG d
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♦ No oil or coolanty Vmust
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Ensure thats acylinder
ut head gasket seals properly: or
ac
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♦ Carefully remove remains of emery and abrasives.
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cardiagn.com
an
itte
♦ Do not remove new cylinder head gasket from packaging

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until it is ready to be fitted. ab

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♦ Handle the cylinder head gasket very carefully to prevent

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damage to the silicone coating or the indented area of the
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gasket.
spec
es, in part or in w
Avoid damage to open valves.

t to the co
♦ When installing an exchange cylinder head, the plastic

protectors fitted to protect the open valves should not be
rrectness of i
removed until the cylinder head is ready to be fitted.

l purpos
Avoid damage to valves and piston crowns after working on

valve gear.
nform
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♦ Turn the engine carefully at least 2 rotations to ensure that

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♦ When installing a exchange cylinder head, the contact surfa‐

ces between hydraulic compensation elements, roller rocker
fingers and cams must be oiled before installing the cam‐
shafts.
♦ Hose connections and air duct pipes must be free of oil and
grease before assembly.
♦ Secure all hose connections with the same type of hose clips
as original equipment ⇒ Electronic parts catalogue .
♦ In order to be in a position to securely attach the charge air
hoses on their connections, the worm screws of the used hose
clips have to the sprayed with penetrating spray before instal‐
ling.

– Position cylinder head gasket.

♦ Note centring pins in cylinder block -arrows-.
♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
Caution
When turning the crankshaft, pull the timing chain upwards

until taut so that it does not become jammed.
– If crankshaft has since been turned, position cylinder number

1 piston to TDC and then turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Tighten cylinder head:
Tightening sequence
⇒ Fig. ““Cylinder head - tightening sequence, camshaft instal‐
led”“ , page 138
cardiagn.com
Tightening sequence
⇒ Fig. ““Cylinder head - tightening sequence, camshaft re‐
moved”“ , page 138
– Install camshafts if removed ⇒ page 183 .
Caution
When turning the crankshaft, pull the timing chain upwards

until taut so that it does not become jammed.
gen AG
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– Fit camshaft timing chain on sprockets. To do this, align mark‐

ings on chain links -arrows- with markings on sprockets -1-.
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– Install upper guide rail -2-.

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teeth -2-.
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Rep. gr.15 - Cylinder head, valve gear Prote AG.
– Check markings. Markings on camshaft timing chain and cyl‐

inder head -arrows- must align with markings on sprockets
-1-.
– Markings on camshaft timing chain and on guide rail of cam‐
shaft timing chain -2- must also align.
– Notch on vibration damper must align with marking on lower
timing chain cover -3-.
Note
If the previously marked markings are not visible anymore, check

valve timing ⇒ page 133 .
– Fit bearing saddle uniformly. Do not cant bearing saddle!
cardiagn.com
Screw in bolts -arrows- and tighten by hand.
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– Depending on version, remove locking pin -wT40011-
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– Change engine oil.

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– Add coolant ⇒ page 235 .

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2.4.2 Removing and installing cylinder head and camshaft timing chain
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equipment required
CCZB, CCZC, CCZD,
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♦ Torque wrench - V.A.G agen

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♦ Cylinder head bolts with
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multi-point socket: Multi-

point socket 12 mm
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♦ Lifting tackle - 2024 A-

♦ Puller - T40039-
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♦ Before the cylinder head is removed, the engine support and
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engine mounting must be reinstalled temporarily, because the
eyes of the support bracket are secured to the cylinder head.
cardiagn.com
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♦ Fit the cable ties in the original position when installing.
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♦ Seal open channels of intake and exhaust system with suitable

plugs from engine bung set - VAS 6122- .
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– Remove air filter housing ⇒ page 459 .
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WARNING Prote AG.
Danger of scalding due to steam and hot coolant.

On a warm engine, the cooling system is under high pressure.
Reduce excess pressure by covering the cap of the coolant
expansion tank with cloths and opening it carefully.
– Open filler cap on expansion tank.

– Remove front exhaust pipe with catalytic converter:
Passat, CC ⇒ page 517
Tiguan ⇒ page 543
– Remove front right wheel.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
exterior; Rep. gr. 66 ; Wheel housing liner .
– Drain coolant ⇒ page 235 .

agen 4-cyl. injection
AG. Volkswagen AG d engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
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– Remove bolt -1- and take out air pipe downwards.
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– Separate electrical wiring connections -1 and 2- and place

electrical wiring to one side -arrows-.

Vehicles with seat heating:

– Unscrew bolts -1 and 2- and move coolant pipes to the left.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
AG. Volkswagen AG d
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– Remove bolts -1 riseand
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– Remove banjo bolt -2- and move coolant pipe clear to one
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side.
Vehicles with front-wheel drive:
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– Remove bolts -1- on oil return line.

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– Remove bolts of oil return line at crankcase.

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– Remove bolt -3- on oil supply line.

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– Pull connector -1- off camshaft control valve 1 - N205- .
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– Detach connectors from ignition coils and place wiring harness

to one side.
– Remove ignition coils using puller - T40039- .
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– Press release tabs -2-, and pull crankcase breather off air
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Engine codes CBFA, CCTA, CCTB:


case breather.
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WARNING
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The fuel line is under pressure.
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Fuel poses danger of injury to eyes and skin.
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Wear protective goggles and protective clothing to avoid injury
cardiagn.com
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
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carefully opening the connection.

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– Detach lines -1 to 3- from the fuel transfer point.

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– Disconnect coolant line to coolant expansion tank -arrow-. cted agen
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– Remove coolant hoses -arrows- from coolant pipe.

– Unbolt earth cable -3- and loosen bolt -4-.

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– Unscrew bolts -1…3- and remove heat shield together with
form
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coolant pipe.
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– Unscrew oil supply line -4- from turbocharger.

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Note
Unscrew bolt -2- from heat shield using a 6 mm hex key -A-. The
hexagon faces must be at least 5 cm long -B-. A socket which
tapers to 6 mm at the tip is too thick.
– Pull off electrical connector -2- from fuel pressure regulating

valve - N276- .

Engine code CBFA:

– Pull connector -A- and hose -B- from secondary air inlet valve
- N112- .
– Loosen coolant pipe by unscrewing bolts -arrows-.
cardiagn.com
All:
– Pull coolant hose from union on side of cylinder head.
– Expose electric cable -5-.
– Pull off vacuum line -6- leading to activated charcoal filter.
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Rep. gr.15 - Cylinder head, valve gear
All:
– Disconnect electrical connectors -1- and detach connectors
from retainer.
– Unscrew bolts -arrows- and detach coolant pipes from intake

manifold.
AG. Volkswagen AG d
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– Disconnect coolant hoses -arrows- and move clear.

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– Remove camshaft timing chain ⇒ page 113 .

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– Detach spindles of support bracket - 10 - 222 A- .

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– If a cylinder
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un
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⇒ page 183 .
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– If a cylinder head cover with sealing plugs for all cylinder head
bolts is installed, turn sealing plugs -arrows- anti-clockwise in
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direction of -arrow- by 90° and remove.

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– Unscrew ball head -1 … 2-.
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– Remove filler cap.
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Multi-point socket head bolt with shoulder:

– Unscrew and remove cylinder head bolts in the sequence
-1 to 10-.

Polydrive bolts:
– Unscrew cylinder head bolts using polydrive bit and socket -
T10070- in sequence -1 to 5-.
AG. Volkswagen AG d
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Make sureut all hoses/pipes and wiring are removed.
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– Place cylinder head onto soft surface (foam plastic).
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Installing cylinder head:
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Note
♦ Replace bolts that are tightened with specified tightening an‐
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gle.
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♦ Renew gaskets, oil seals and self-locking nuts.

♦ Hose connections and air duct pipes must be free of oil and
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grease before assembly.

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♦ Secure all hose connections with the correct type of hose clips
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tion in
(same as original equipment) ⇒ Electronic parts catalogue .

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♦ Spray the worm screws of the used hose clips with penetrating
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spray before installing.

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– Carefully remove sealant residue from cylinder head and cyl‐
AG.
inder block. Ensure that no long scores or scratches are made

on the surfaces, while doing so. Carefully remove remains of
emery and abrasives.
– Clean blind holes for cylinder head bolts. Blow out with com‐
pressed air if necessary.

– Position cylinder head gasket.

♦ Note centring pins in cylinder block -arrows-.
♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
– If crankshaft has since been turned, position cylinder number
1 piston to TDC and then turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Tighten cylinder head:
Tightening sequence
⇒ Fig. ““Cylinder head - tightening sequence, camshaft instal‐
led”“ , page 138
Tightening sequence
⇒ Fig. ““Cylinder head - tightening sequence, camshaft re‐
moved”“ , page 138
– Using support bracket - 10 - 222 A- , support engine in instal‐
lation position again.
cardiagn.com
– Removing engine mounting and engine support.
– Install camshafts if removed ⇒ page 183 .
– Install drive chain for balance shaft and camshaft timing chain
⇒ page 119 .
The remaining assembly steps are basically a reverse of the dis‐
mantling procedure, when doing this note as follows:
– Change engine oil ⇒ Maintenance ; Booklet ; Engine oil: gen AG. Volkswagen AG d
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– Fill with new coolant ⇒ page 235 . rise tee
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equipment required
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Puller - T40039-
1331-
♦ Compression tester - V.A.G
1763-
♦ Adapter - V.A.G 1381/5A-
♦ Adapter - V.A.G 1381/1-
cardiagn.com
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♦ Observe all relevant safety precautions ⇒ page 552 .

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♦ Engine oil temperature min. 30 °C

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– Removing ignition coils with output stages ⇒ page 553 .
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– Unscrew spark plugs using spark plug socket - 3122 B- .

– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .
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– Install spark plugs, specified torque ⇒ page 553 .
– Install ignition coils with output stages ⇒ page 553 .
rrectness of i
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Note
cardiagn.com
Faults will have been stored in the memory because connectors
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have been disconnected. Read and, if necessary, clear the event

memory after the test.
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– Read event memory of engine control unit ⇒ vehicle diagnos‐
thi
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2.6 Removing and installing vacuum pump

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Proceed as follows:
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– Remove motor cover panel ⇒ page 139 .

– Remove air filter ⇒ page 459 .
– Remove high-pressure pump with »roller tappet«
⇒ page 483 .
– Unbolt earth cable -3- and remove bolt -4-.

– Remove vacuum hose -1- from vacuum pump.
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• Specified torques ⇒ page 135
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– Position gasket on vacuum pump, insert 2 bolts and then po‐ atio
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Assembly overview - valve gear ⇒ page 180 .
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Removing and installing camshafts ⇒ page 183 .
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Checking axial clearance of camshafts ⇒ page 198 .

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3 - Valve guide
❑ Checking ⇒ page 202
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4 - Valve stem seal
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6 - Valve spring plate
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❑ Radial clearance with

bearing ∅ of 24 mm:
0.024 … 0.066 mm
❑ Radial clearance with
bearing ∅ of 32 mm:
0.030 … 0.051 mm
❑ Runout: max. 0.04 mm
10 - Cylinder head cover
❑ With integrated camshaft bearings.
❑ Clean sealing surface; reworking not permitted.
❑ Remove sealant residue.
11 - Bolt
❑ Renew
12 - O-ring
❑ Renew
13 - Plugs
14 - Inlet camshaft
❑ Check radial clearance with Plastigage (roller rocker fingers removed)
❑ Radial clearance with bearing ∅ of 24 mm: 0.024 … 0.066 mm
❑ Runout: max. 0.04 mm
3. Valve gear 181

15 - Cap
❑ Renew
❑ Removing sealing cap with cylinder head cover installed: pierce on one side with an awl and pry out
❑ Installing: press in 1 to 2 mm deep without sealant using thrust piece - T10174-
16 - Inlet valve
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2. Tighten bolts in the sequence -1 … 6- to 8 Nm using torque
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wrench.
3. Turn 90° further in the sequence -1 … 6- using a fixed
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wrench.
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Dimension Inlet valve Outlet valve

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.007 5.955 ± 0.007
c mm 103.97 101.87
α ∠° 45 45

3.2 Removing and installing camshaft

equipment required
CCZB, CCZC, CCZD,
tool - T10352/1-
♦ Locking pin - T40011-
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3. Valve gear 183

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♦ The camshaft bearings are integrated into the cylinder head
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and cylinder head cover. The camshaft timing chain must be
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relieved of tension before you remove the cylinder head cover.

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♦ Renew sealing cap if cylinder head cover has been detached
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⇒ Item 15 (page 182) .
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Removing:
– Remove vacuum pump ⇒ page 178 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview – noise in‐
sulation .
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .

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– Detach connector -1- from camshaft control valve 1 - N205- .
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valve 1 - N205- .
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– Remove upper timing chain cover ⇒ page 90 .
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– Turn vibration damper to “TDC” position -arrow- using coun‐

terhold - T10355- .
3. Valve gear 185

– Mark positions of sprocket markings -1- on camshaft timing

chain and cylinder head -arrows- using a permanent felt tip
marker.
– Also mark alignment of camshaft timing chain -2- relative to
guide rail of camshaft timing chain using a permanent felt tip
marker.
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– Remove sealing plug -arrow-. rise
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– Unscrew bolt -arrow-.
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Depending on version, either of two different chain tensioners

may be installed. Version 1:
Note

cover.

Caution
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– Secure chain tensioner with locking

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– Press together securing clip -arrow- of chain tensioner. Then, cted agen
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slowly push lever - T40243- in -direction of arrow- and hold it
in that position.
3. Valve gear 187


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in direction of arrow -2- between teethaut of sprocket. If necessary
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ss of arrow -1- using span‐ c
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– Turn exhaust camshaft clockwise -1- until camshaft clamp -

T40271/1- can be inserted into sprocket splines.
– Use screwdriver to release fastener and press off top guide
cardiagn.com
rail towards front -1-. Mark position of sprockets -arrow- rela‐
tive to camshaft clamp.
– Remove camshaft timing chain from camshaft sprockets.
Caution
Risk of damaging valves, piston crowns and lower timing chain

cover.
♦ Ensure the timing chain is always under tension when
turning the crankshaft.
♦ Plates to prevent the chain falling down are attached to G. Volkswagen
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earlier must be transferred. To do so, proceed as follows:

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– Before removing camshafts, mark alignment of camshaft

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shaft clamp - T40271/2- -arrow-.

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The following measurement of distances is later used to check

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3. Valve gear 189


-B- on inlet camshaft and record figure.
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– Measure distance from marking on inlet camshaft -B- to mark‐ le
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– Turn inlet camshaft in -direction of arrow 1- using spanner,
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remove camshaft clamp - T40271/2- in -direction of arrow 2-
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from between teeth of sprocket and bring camshaft into rest
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position.
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– Turn exhaust camshaft in -direction of arrow 1- using spanner,

remove camshaft clamp - T40271/1- in -direction of arrow 2-
from between teeth of sprocket and bring camshaft into rest
position.
– Removing ignition coils with output stages ⇒ page 553 .
Engine codes CCZA, CCZB, CDAA, CDAB:
cardiagn.com
– Separate crankcase breather hoses -1 and 2-.
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3. Valve gear 191

All:
– Disconnect vacuum line -1- and move line to one side.
– Pull off connector -2- from Hall sender - G40- .
– Undo and remove cylinder head cover bolts in the sequence

-1 … 6-.
– Remove cylinder head cover.
– Detach camshafts.
– Prevent dirt and residual sealant from entering cylinder head.
Installing camshafts
cardiagn.com
If new camshafts are to be fitted, transfer the markings which you
made on the removed camshafts to the new ones.
• Specified torques ⇒ page 180
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♦ After installing camshafts
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silicone sealant.
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♦ Prevent dirt and residual sealant from entering cylinder head.

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– Remove sealant remaining on cylinder head with flat scraper.

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– Remove sealant left in groove of cylinder head cover and on

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– Renew bolts for cylinder head cover.
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– Apply silicone sealant - D 154 103 A1- onto clean sealing sur‐
face of cylinder head cover, as illustrated -arrows-.
Note
♦ The cylinder head cover must be installed within 5 minutes

after applying the silicone sealant.
♦ Check the expiry date of the sealant.
– Tighten bolts in several stages; tightening sequence

⇒ page 182 .
3. Valve gear 193

Note
♦ Take care to keep cylinder head cover level.

♦ Use thrust piece - T10174- to drive in sealing cap -1- without
sealant.
♦ Dimension -a-: 1 to 2 mm
Caution
Risk of damaging valves, piston crowns and lower timing chain

cover.
♦ Ensure the timing chain is always under tension when
turning the crankshaft.
♦ Plates to prevent the chain falling down are attached to
the lower timing chain cover. If the crankshaft is turned
when the chain is loose, the plates may bend.
cardiagn.com
– Turn vibration damper to »TDC« position -arrow- using coun‐
terhold - T10355- .
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– Turn inlet camshaft in -direction of arrow 1- until marking -3-

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aligns with camshaft clamp - T40271/2- .

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– Turn exhaust camshaft in direction of arrow -1- until marking

-3- aligns with camshaft clamp - T40271/1- .
– Insert camshaft clamp - T40271/1- in -direction of arrow 2- be‐
tween teeth of sprocket.
Procedure for new camshafts:
– Compare distance from left outer edge of web -A- to marking
cardiagn.com
-B- with figure recorded earlier.
G. Volkswagen
– Compare distance from marking on inlet camshaft
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– Fit camshaft timing chain on sprockets. To do this, align mark‐

ings on chain links -arrows- with markings on sprockets -1-.
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– Install upper guide rail -2-.

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Have a second mechanic hold the exhaust camshaft.

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3. Valve gear 195


teeth.
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– Check
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and
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cylinder head -arrows- must align with markings on sprockets
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– Markings on camshaft timing chain and on guide rail of cam‐
ility
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shaft timing chain -2- must also align.
wit
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– Notch on vibration damper must align with marking on lower
hole
spec
timing chain cover -3-.
es, in part or in w
t to the co
Note
rrectness of i
If the previously marked markings are not visible anymore, check
valve timing ⇒ page 133 .
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– Fit bearing saddle carefully. Do not cant bearing saddle! Screw
o
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f
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in bolts -arrows- and tighten by hand. en
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– Depending on version, remove locking pin - T40011- or locking
. C rig
ht ht
tool - T40267- .
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– Screw in bolt -arrow-.

Note
If the markings on the camshaft timing chain and the guide rail
-2- no longer align even though the engine is at »TDC«, the drive
chain may have jumped on the crankshaft sprocket. Check valve
timing ⇒ page 133 If the timing is not correct, the camshaft timing
chain has to be taken off and fitted »again« ⇒ page 113 .

quence.
3. Valve gear 197

3.3 Checking axial clearance of camshafts

♦ Universal dial gauge holder - VW 387-
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Test sequence
– Perform measurement with retaining frame removed.
– Fit camshaft to be tested in retaining frame. agen
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– Attach dial gauge - VAS 6079- with universal dial gauge holder d by
V gu
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- VW 387- to cylinder head. orise nte
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– Press camshaft against dial gauge by hand. ss a c ce
le
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– Set dial gauge to “0”.

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– Press camshaft away from dial gauge and read off value:
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• Axial clearance: 0.05 to 0.17 mm

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3.4 Renewing valve stem seals

spec
t to the co
(With cylinder head installed)

rrectness o
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198
AG.
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n AG. V➤olks,wGolf 2009
agen AG do ➤ , Passat 2006 ➤ , ...
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4-cyl. injection engine
by (1.8
Vol and 2.0 l engine, chain drive)
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Special tools and workshop au
th e or
ac
equipment required ss
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♦ Spark plug socket and ex‐
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tension - 3122 B-
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♦ Valve stem seal puller -
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3364-
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♦ Valve stem seal fitting tool -
spec
3365-
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t to the co
♦ Adapter - T40012-
rrectness of i
1331-
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♦ Removal and installation

device - VAS 5161-
nform
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♦ Guide plate for 2.0 l and 3.0

l FSI engine - VAS
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5161/19B-
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Removing valve stem oil seals:

– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Remove spark plug with spark plug socket and extension -
3122 B- .
– Secure guide plate - VAS 5161/19B- with knurled screws -
VAS 5161/12- to cylinder head as shown.
– Set piston of the respective cylinder to “bottom dead centre”.
3. Valve gear 199

– Screw adapter - T40012- into spark plug hole and connect to

compressed air supply of at least 6 bar.
– Knock loose sticking valve cotters using punch - VAS 5161/3-
and a plastic-headed hammer.
For inlet side

– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into centre thread of guide plate - VAS 5161/19B- .
– Insert assembly cartridge - VAS 5161/8- into guide plate - VAS
5161/19B- .
– Attach pressure fork - VAS 5161/2- to snap-in device - VAS
5161/6- .
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For exhaust side
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into outer thread of guide plate - VAS 5161/19B- . olksw AG. V agen AG
agen does
– Press down assembly cartridge - VAS 5161/8- olks . At the same
w not
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time, turn knurled screw of assemblysecartridge
d b - VAS 5161/8- ara
nte
clockwise until ends engage in valve
tho cotters.
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– Move knurled screw back and forth
ss lightly to press apart valve
ce
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cotters and capture them in the assembly piece.

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– Release the pressure fork - VAS 5161/2- .

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– Remove assembly cartridge - VAS 5161/8- .

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hole
– Pull off valve stem seals using valve stem seal puller - 3364- .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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CC
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. Volkswag,en
Eos
AG d2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
wage oes
Volks 4-cyl. injection enginenot (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
gu
by ara
ed nte
ris
– If valve
uth stem seal puller - 3364- cannot be used due eto
o
or restric‐
tedsspace,
sa knock out pin -arrow- with a punch and remove ac
the
impact extractor attachment.
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e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Position lower part of valve stem seal puller - 3364- on valve
l purpos
stem seal.
– Insert a punch -1- through hole in lower section of puller.
nf
ercia
orm
– Apply a lever to puller device and pull out valve stem seal
m
atio
m
-arrow-.
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n in
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Installing valve stem seals:
AG.
– To prevent damage to new valve stem seals -B-, attach plastic

sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool - 3365- and push carefully onto
valve guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
Inlet side
– Set up disassembly and assembly tool - VAS 5161- as shown.
3. Valve gear 201

Exhaust side
– Set up disassembly and assembly tool - VAS 5161- as shown.
Note wage
es n
olks ot g
byV ua
♦ If the valve cotters have beenrisremoved
ed from the installation ran
tee
cartridge, they must first be uthinserted into the insertion device
o
or
- VAS 5161/18- . ss
a ac
ce
e
nl
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
pt
du
an
from above and pick up valve cotters.
itte
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ility
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– Press assembly cartridge - VAS 5161/8- down using pressure
wit
, is n
fork - VAS 5161/2- and turn knurled screw of assembly car‐
h re
hole
tridge back and forth while pulling upwards.
spec
es, in part or in w
– Release the pressure fork - VAS 5161/2- with knurled screw
t to the co
still in pulled-out position.
– Disassemble removal and installation device - VAS 5161- as
rrectness of i
shown.
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quence.
nf
ercia
3.5 Checking valve guides

rm
m
atio
om
n in

or c
thi
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♦ Universal dial gauge bracket - VW 387-

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Test sequence
– Insert valve in guide. Valve stem end must be flush with guide.
On account of differing stem diameters, only use inlet valve in
inlet guide and exhaust valve in exhaust guide.
– Determine rock.
Wear limit
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AG. Volkswagen AG d
Inlet valve guide lksw
Exhaust
agen valve guide oes n
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0.80 mm isedb 0.80 mm ua
ran
or tee
h
aut or
ac
ss
Note
ce
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nl
pt
du
an
itte
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♦ If the wear limit is exceeded, repeat the measurement with
erm
new valves. If the wear limit is exceeded again, renew the cyl‐ ab
ility
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inder head. wit

, is n
h re
♦ If the valve is to be renewed as part of a repair, use a new
hole
spec
valve for the calculation.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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by
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Prote AG.
3. Valve gear 203

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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...

15 – Cylinder head, valve gear

Assembly overview - camshaft timing chain ⇒ page 111 .

Assembly overview – drive chain for balance shaft ⇒ page 125 .

1.1 Assembly overview - timing chain covers

❑ Lubricate before as‐

❑ To renew, remove cover

Golf, Eos, Scirocco ⇒ page 98

Tiguan ⇒ page 105

88 Rep. gr.15 - Cylinder head, valve gear

Timing chain cover (top), tightening sequence

– Tighten bolts -1 to 15- in two stages in the sequence shown:

– 2. Turn bolts 45° further.

Lower timing chain cover – tightening sequence for version with

– Tighten bolts -1 to 8- in 2 stages in the sequence shown.

1.2 Removing and installing camshaft con‐

1.3 Removing and installing upper timing

Vehicles with activated charcoal filter in engine compartment:

90 Rep. gr.15 - Cylinder head, valve gear

– Unscrew coolant pipe bolts -arrows- from intake manifold.

– Lubricate gasket and O-ring with engine oil.

– Position cover on engine, ensuring that gasket is correctly

– Hand-tighten bolts -1 to 5- evenly in the sequence shown:

– Further tighten bolts to 9 Nm. Use torque wrench - V.A.G 1783-

– Install inlet camshaft control valve 1 - N205- ⇒ page 90 .

– Tighten bolts -arrows- for guide tube.

chain cover (Passat, CC)

Special tools and workshop equipment required

♦ Assembly tool - T10531-

92 Rep. gr.15 - Cylinder head, valve gear

♦ Passat 2006▶: Rack - 10 - 222 A /1-

♦ CC: Adapter - 10 - 222 A /8-

♦ Silicone sealant - D 174 003 M2-

♦ The adapters - 10 - 222 A /8- must not be located on the screw

in its installation position and does not »fall back«.

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

– Raise engine approx. 50 mm and loosen upper engine support

– Now lower engine approx. 100 mm.

– Move electrical wiring harness clear -arrow-.

94 Rep. gr.15 - Cylinder head, valve gear

Risk of damaging lower timing chain cover. To prevent dam‐

– Lever off lower timing chain cover, starting at points

♦ If the cover was bent during removal, it must be renewed.

♦ Wear safety goggles.

– Remove sealant residues from cylinder block with a flat scra‐

seal remains clean.

– Remove remaining sealant from cover, e.g. using rotating

– Clean sealing surfaces. They must be oil and grease free.

Checking cover for distortion:

– Fit cover using old bolts and tighten to 8 Nm.

♦ Renew cover if distance exceeds 0.2 mm.

96 Rep. gr.15 - Cylinder head, valve gear

Cover with 15 bolts

– Apply silicone sealant - D 174 003 M2- to clean sealing surface

-arrow 1- and to edges -arrows 2- of new cover as shown in

Cover with 8 bolts

♦ The cover must be installed within 5 minutes after applying the

– Install cover immediately and tighten bolts:

98 Rep. gr.15 - Cylinder head, valve gear

Special tools and workshop

♦ Assembly tool - T10531- AG. Volkswagen AG d

– Drain engine oil.

100 Rep. gr.15 - Cylinder head, valve gear