CC 2010 > , Eos 2008 ~ , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Cylinder head, valve ge 41 Chain drive Assembly overview - timing chain covers > page 87 Removing and installing inlet camshaft control valve 1 - N205- > page 20 Removing and installing upper timing chain cover = page 90 Removing and installing lower timing chain cover (Passat, CC) > page £2 Removing and installing Jower timing chain cover (Golf, Eos, ‘Sci acco) = page 98 Removing and installing lower timing chain cover (Tiguan) = page 105 Assembly overview - camshefft timing chain = page 111 Removing ’and installing camshaft timing chain = page 113 ‘Assembly overview - drive chain for balance shaft > page 125 Removing and installing drive chain for balance shaft = page 127 Remauing and intaling balance shaft for inlet camshaft > page 127 Remdving and installing balance shaft for exhaust camshaft > page 130 Check valve timing = page 133 14 Assembly overview - timing chain covers g 1.chain dive 87CC 2010 > , Eos 2006 > . Golf 2004 > . Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2,0 L.enginey/chain crive) - Edition 02.2017 1-O-ring Renew Lubricate before as! sembling. 2 - Dipstick guide tube 3. Bolt Q 9Nm 4 Bolt Q 9Nm 5 Inlet camshaft control valve 4-N205- Removing ane instaling = page 6 - Sealing ring = O Lubricate before as- sembiing. Renew if damaged lo- 1 Torenew, remove cover 7- Bolt 1D Tightening sequence! = page 90 ss 8 - Timing chain cover (top) Removing and instaling = page 90 Tightening sequence =page 88 15 1413 12 11 9- Seal Renew if damaged 10- O-ring Renew Lubricate before assembling, 14 - 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 Removing and installing Passat CC = page 92 Golf, Eos, Scirocco = page 98 Tiguan = page 105 13- Bolt O 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 ep or.15- Cynder noad. valve gearCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 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 Lower timing chain cover - tightening sequerice for version with 15 bolts = Tighten bolts -1 to 15- in two stageS in the sequence shown. = 1. Tighten boits to 8 Nm. — 2. Tum bolts 45° further. Lower timing chain cover - tighte 8 bolts = Tighten bots 1 to 6 n2stages ine, sequence shown, — 1, Tighten bolts to 8 Nm. °%y = 2. Tum bots 45 futher ing sequence for version with 1.chain dive 894-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 1.2 Removing and installing camshaft con- trol valve 1 - N205- = IFfited, remove charge air duct to sound generator = page 447 = Detach connector from inlet camshaft control valve 1 - N205- — 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 oi 13 Removing and installing upper timing chain cover ‘Special tools and workshop equipment required # Torque wrench - V.A.G 1783- VAG 1763 # Open-end spanner insert (10 mm) - VAG 1783/1- Removing = Remove engine cover panel = page 439 — Only vehicles with sound generator: Open catch -1-, unclip fuel lines -2- and! loosen bolt -3- on activated charcoal fitter. Place charge air pipe to one side. 8 Vehicles with activated charcoal filter in engine compartment: 90 ep. or.15- Cynder noad. valve gearCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Pull off breather line -1-, release activated charcoal fiter -A- snd remove upwards -B. Place activated charcoal fit 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 vaive 1 - N205- Unscrew bolts -1...5- and remove upper timing chain cover. (nee ens Unscrew loner bolts -3- and -5- using an open-end spanner. Installing: — Lubricate gasket and O-rieg with engine oil. = Position cover on enginé, ensuring that gasket is correctly seated. ~ Hanés-tighten bolts 1 to 5- evenly in the sequence shown: — 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 Band-5. — Install inlet camshaft control valve 1 - N205- = page 90 1.chain dive 91@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy. injection engine 1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Tigaiter olts -arrows- for guice tube. (B) Nowe Ifthe mounting holes don't align, check ifthe guide tube has been inserted to stop into tie lower timing chain cover. + Specified torques = page 87 Further assembly is basically @ reverse of the dismantling se- lence y 9 s 14 Removing and installing lower timing chain cover (Passat, CC) ‘Special tools and workshop equipment required # Pin-T10060 A- s T10060A # Counterhold tool - 110355- # Assembly tool - T10531- 92 Rep. or.15- Cynder head. valve gearCC 2010 > . Eos 2006 ~ , Golf 2004 > . Golf 2009 > , Passat 2006 > , ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Bits - T10099. @ Support 10-222. A. < Ss SS © Passat 2006 Rack - 10 - 222 A/1- © CC: Adapter - 10 - 222 A18- Silicone sealant - D 174 003 M2- Removing = Remove vibration damper = page 50 = Drain engine oil — Support engine in installation position, 1.chaindive OS4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Passat 2006" # Rack - 10-222 A/1- % Hook - 10-222 A /10- # Shackle - 10-222 A/12- ce: # Adapter - 10-222 A/a # Hook - 10-222 A/10- # Shackle - 10-222 4/12. ( now + The adapters - 10- 222A /6. must not be located on the screw plates ofthe wings, as ths wil otnerwise cause damage to then. 4% The shackle - 10- 2224/12. is needed'so the engine. ra.scd «ns installation positon and does not »fal! back«. Alt = Take up weight 0. engine with spindle Unscrew bolts -arrows- of engine/gearbox support on the en- gine. = Remosing engine mouning = page 21%, = Reise engine approx. 50mm and loosen Upper engine support bolt. — Now lower engine approx. 10U men. = 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. 94 ep. r.15- Cynder noad. valve gearCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Remove bolts -arrows- and pilll guide tube for oil dipstick out of timing chain cover. — Remove charge pressure solenoid valve - N75- from turbo- charger -arrows- Remove turbocharger connection -1~. = Unscrew bolts -1 ... 15- (nae Depending on version, the cover may be secured with onty is A Caution Risk of damaging lower timing chain cover. To prevent dam- aging the ting chain cover. pp too only at te bolt holes. 1.chain dive OS@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Lever off lower timing chain cover, starting at points A and 2-. Installing # Specified torques > page 87 # Sealant: Silicone sealant - D 174003 M2 4 ifthe cover was bent during removal, it must be renewed. # Note expiry date of silicone sealant. The covermust be installed within 5 minutes after applying the silicone sealant. SWagon A 4 Renewbots which ils be tightened futher tore angle. @ Renew seals; gaskets and self-locking nuts. 0, LX g casion x © Danger of contaminating lubrication system! Gover open S parlor engine + Wear safety goggles. % ~ [Remove sealant residues from cylinder block with a flat scra- z Per. Mask oil seal on both sides with adhesive tape to make sure g ‘seal remains clean. = Remove remaining sealant from cover, eg. using rotating plastic brush. ‘Clean sealing surfaces. They must be oil and grease free. Checking cover for distortion: ~ Fit cover using old bolts and tighten to 8 Nm. ~ Use foster gayge to measure distance o cover and housing (max. distance is 0.2 mm). (@ note ay yates # Renew cover if distance exceeds 0.2mm. + itis notpossible to measure distance between coverand sump (top section); check visually to ensure that sealing surface is even. 96 ep. or.15- Cynder head. valve gearCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... @ ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Installing cover: — fnecessary, :nserew fange nut -T10531/4- , and remove turning over too! - 710531/3- ~ Shack that beth dowel pins for centting the cover -arows- wre ‘ite = Cut off nozzle on tube at front marking (2 of nozzle approx. 2 mm. Cover with 15 bolts - Apply silicone sealant -D 474 003 Mi2- to clean sealing surface -arrow 1- and to edges -arrows 2- of new cover as shown in illustration. 5 Thickness of sealant bead: 2 to 3 mm. 1.chain dive O74-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Cover with 8 bolts — Apply silicone sealant-C 174.003 M2-to clean sealing surface -arrow 1- and to edges -arrows 2- of new cover as shown in ilustration. # Thickness of sealant bead: 2 to 3 mm, (Fee The cover must be installed within 5 minutes after applying the silicone vealant. The bead of sealant must net b. thicker than specified, other- wise excess sealant can enter th. su) sp and obstruct the strainer in the ofl intaxe pive. ~ Install cover immediately and tighten bolts: % Cover, version with 15 tolts = page 89 # Cover, version with 8 bolts = page 89 = Install vibration damper = page 50 Further assembly is basically a reverse of the dismantling se- quence. (@ Nowe After fitting cover, Jet sealant dry for approx. 30 minutes. Only then fill with engine ov. = Replenish engine oil and check oil level. 15 Removing and installing lower, timing chain cover (Golf, Eos, Scirécco) 9B Rep. or.15- Cynder noad. valve gearCC 2010 > , Eos 2006 ~ , Golf 2004 > . Golf 2009 > , Passat 2006 ~ , ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 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- Counterhold tool - 110355- 10-222 AN10 “a Sy Cc 1.chain dive 994-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 # Assembly tool - 110531- # Eos, Scirocco: Rack - 10 - 222 A/1- Removing = Remove vibretion damper = page 50 =. Drain engine oil 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 4/13. aty. 2 # Hook - 10-222 4/10- # Shackle - 10-222 A/12- 102th Ih 100 Rep. o.15- cytindsr head, valve gearCC 2010 > , Eos 2006 ~ , Golf 2004 > , Golf 2009 > , Passat 2006 > , cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Eos, Scirocco: @ Rack - 10-222 A/t- @ Hook - 10-222 4/10- @ Shackle - 10 - 222 A/12- [F) Note @ The rack feet- 10-222 A/1- must not be placed on the bolted ‘on sheet met 2fthe wings, or these might be damaged. @ The shackle - .0-222/A/1z- is needed so the engine is raised 17 ts installation position and does not »fall back. Al: = Take up weight of engine with spindle. = Unscrew bolts -arrows- of engine/gearbox support on the en- gine. — Rervoving engine mounting + page 21 Raise engine approx. 50 mm and loosen upper engine support bolt. = Now lower engine appro::. 100 mm. = Move electrical wiring hamess clear -arrowe = Remove holt -1- and tale off tensioning device for poaly’'V-belt from bracket for ancillaries = Unscrew lower bolts for engine support using bits - T10089- ~ Remove engine support with bolts. — Remove bolts -arrows- and pull guide tube for oil dipstick out of timing chain cover. © 1.chain dive 101@ - Remove charge’ pressure solenoid valve - N75- from turbo- charger -arrows. = Remove turbocharger connection -1-. Unscrew (F] now Risk of damaging lower timing chain cover. To prevent dam- aging the timing chain cover. apply tool only at the bolt holes. 102 pep. 18 -Cyindr nad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Lever off lower timing chain cover, starting at points -tand 2-. Installing: © ‘Specified torsues = pace 87 Sealant: Silicone sealant - D 174 003 M2- [F) Note ¢ If the cover was bent during removal, it must be renewed. ¢ Note expiry date of siicone sealant. The cover must be installed within 5 minutes after applying the Silicone sealant. ¢ Renew bolts which must be tightened further to a torque angle. ¢ Renew seals, gaskets and sel-locking nuts. LX couton '# Danger of contaminating lubrication system! Cover open parts of engine. ¢ Wear safety goggles. — Remove sealant residues from cylinder block with a flat scra- Per. — Mask oil seal on both sides with adhesive tape to make sure teal remains clean = Remove remaining sealant troméSver, e.g. using rotating plastic brush, — Clean sealing surfaces. They must be oil and grease free. Checking cover for distortion’ ~ Fit cover usitig old bolts and tighten to 8 Nm — Use feeler'gauge to measure distance between cover and housing (max. distance is 0.2 mm). © Reneiv cover if distance exceeds 0.2 mm. ¢ Itisnotpossible tomeasure distance between cover andsump (top section); check visually to ensure that sealing surtace is even. 1.chandive 103@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Installing cover: — If necessary, unscrew flange nut -710531/4-, and remove tuming over tool - T10531/3- ~ Shack that bth dowel pins for sefising the cover-arrows- ere ited. > = Cutoff nozzle an tube at frant marking (2 of nozzle approx. 2 mm). & x 2 Cover with 15 bolts "P05 ry oo ~ Apply silicone sealant -D 174 003 M2-to clean sealing surface -arrow 1- and to edges -arrows 2- of new cover as shown in illustration. # Thickness of sealant bead: 2 to 3 mm, 104 ep. o-15-Cyindr noad, vate gsarCC 2010 > , Eos 2006 ~"/'Golf 2004 > , Golf 2009 > , Passat 2006 > , @ Acyl. injection engine (1.8 arid 2.0 | engine, chain drive) - Edition 02.2017 Cover.with 8 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 illustration ‘@ Thickness of sealant bead: 2 to 3 mm. w) ne The cover must be installed within 5 minutes after applying the silicone seslant © The bead of sealant must not be thicker than specified, other- wise excess sealant van enter the sump and obstruct the strainer in the ol intake pipe. Install cover immediately and tighten bolts: ©.Cover, version with 15 bolts = page 69 Cover, version with 8 bolts > page 89 = Install vibration damper = page 50 Further assembly is basically a revers&sef the dismantling se- quence. (&) note After fiting cover, let sealant dry for approx. 30 minutes. Only then fil with engine oil = Replenish engine oil and check oil level. 16 Removing and installing bottom timing chain cover (Tiguan) Special tools and workshop e;uipment required # Support - 10.2228 ‘Shackle - 10-222A/12- Adapter - 10-2224/16- Adapter - 10-2224/18- Adapter - 10-222A/22- Adapter - 10-2224/28- eee ee S 1.chaindive 105@ CC 2010 > , Eos 2006 ~ Gel 2004 > , Golf 2003 **;;Passat 2006 ~ ... 4-cyl. injection engine(4.8 and 2.0 | engine, chain drive) - Edition 02.2017 # Square tube - T40094/1- # Swivel joint - T40091/3- # Pin. T1060 A T10060 A w| ? # Counterhold tool - 110355- 710355, # Assembly tool - T10531- (or 106 Rep. o.15- cytindsr nead, valve gearAcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2047 ¥ sits - T10099- silicone sealant - D 174 003 M2 Removing — Reniove vitration dmper > page 50 = Drain engine oil — Remove motor cover panel > page 139 = 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. = Take up weight of engine witis spindle. = Unscrew bolts -arrows- of engifje/gearbox support on the en- gine. = Removing engine mounting = page 21 Raise engine approx. 50 mm and loosen upper engine support bolt. — Now lower engine approx. 100 mm, chain dive 107@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Move electrical wiring harness clear -arrow- — Remove bolt -1- and take otf tensioning device for poly V-belt from bracket for ancillaries. — Unscrew lower bolts for engine support using bit - 10099 ~ Remove engine support with bolts. — Remove bolts -arrows- and pull guide tube for oil dipstick out of timing chain cover. — Remove charge pressure solenoid valve - N75- from turbo- charger -arrows- ~ Remove turbocharger connection -1-. vee = Unscrew bolts -1 ... 46. (F) noe Depending on version, the cover may be secured with only 8 Risk of demaging lower timing chain cover. To prevent dam- ging the timing chain cover, apply tool only at the bolt holes. 108 | ep. o-18-cyindr naad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 — Lever off lower timing chain cover, starting at points Sand 2-. Installing © ‘Specified torques = pace 87 Sealant: Silicone sealant - D 174 003 M2- [F) Note ¢ If the cover was bent during removal, it must be renewed. ¢ Note e pity date of siicone sealant. ¢ The cover must be installed within 5 minutes after applying the Silicone sealant. ¢ Renew bolts which must be tightened further to a torque angle. ¢ Renew seals, gaskets and sel-locking nuts. Ay cnn pm merneng '# Danger of contaminating lubrication system! Cover open paris ofengine. > ¢ Wear safety goggles. Remove sealant residues from cylinder block with a fiat scra- Per. Mask cil seal on both sides with adhesive tape to make sure seal remains clean. Remove remaining sealant from cover, e.g. using rotating Plastic brush, Clean sealing surfaces. They must be oil and grease free. Checking cover for distortion: ~ Fit cover using old bolts and tighten to 8 Nm. — Use feeler gauge to measure distance between cover and housing (max. distance is 0.2 mm). © Renew cover if distancé exceeds 0.2 mm. Itisnotpossible to measure distance between cover daa sump (top section); check visually to ensure that sealing stface /s, even. > 1.chain dive 109@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 — Ifnecessary, unserew ange nut - 710521/4- , and remove. tuming over tool - T10831/2- ~ Shack that both dowel pine fr centring the cover -rrows- are tte = Cutoff nozzle on tube at front marking (2 of nozzle approx. 2 rm). ‘Sover-with 15 bolts ~ Apply silicone sealant-D 174 0C3 v12- to clean sealing surface ~arrow 1- and to edges -arrows 2- of new cover a ilustration. # Thickness of sealant bead: 2 to 3 mm, in 110 ep. o-15-Cyindr nad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain crive) - Edition 02.2017 Cover with 8 bolts — Apply silicone sealant-D 174003 M2-toclean sealing surface “arrow 1 and to edges -arrows 2. of new cover as shown in illustration. ‘ Thickness of sealant bead: 2 to 3 mm. (me © The cover must be installed within 5 minutes atter epplying the silicone sealant ¢ The bead of sealant must no. be thicker tnan specified, other- wise excess sealans ran enter the sump and obsiruct the swraine*ip the ol intake pipe. — _.nstall cover immediately and tighten 2olts: © Cover, version with 15 bolts = page 69 Cover, version With 8 bolts = page 89 ~ Install vation dartper = page 50 a ting 960 Further assembly is basically &'ceverse of the dist quence. (&) note After fiting cover, let sealant dry for approx. 30 minutes. Only then fil with engine oil. = Replenish engine oil and check oil level. 1.7 Camshaft timing chain - exploded view 1.chain dive 1114-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 1 - Bolt 2 Nm 2- Chain tensioner Q Isspring-loaded Depending on version, secure with locking pin - T40011- or locking tool - 740267-. 3 - Tensioning rail for timing chain 4 - Guide pin 20Nm 5 - Bolt O 9Nm 6 - Regulating valve Left-hand thread 0 35Nm _ Kemove with assembly tool - T10352- Engine codes COZA, CCZzB, CCZC, CCZD, CDAA\ CDAB: use as- sembly tool - T10352/1- to remove 7 - Bolt O Renew M6: 8 Nm + 90° further (M8: 20 Nm + 90° further 8 - Washer 9- Bearing saddle 10 - Guide rail for camshaft timing chain . 11 - Camshaft case 12 - Camshaft timing chain Q Before removing, mark running direction with paint Removing and installing > page 113 13 - Guide rail for camshaft timing chain 14 Guide pin @ 20Nm 15 - Chain sprocket Q Crankshaft O Fitting position + page 113 112 ep. o-18-Cyindr noad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Crankshaft chain sprocket - installation position + The two sections -arrows- must be aligned. 18 Removing and installing camshaft timing chain Special tools and workshop equipment required # Assembly tool - T10352- Engine codes COZA, CCzB, CCZC, CCZD. CDAA COAB: assembly} tool - T10352/1- Coyntérhold tool - 110355- 2ocking pin - 740011- Assembly lever - T40243- Locking tool - T40267- Camshaft clamp - 740271- ee bee iY 1.chaindive 113CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.. and 2.0 | engine, chain drive) - Edition 02.2047 # Assembly tool - 110531- Components of assembly tool - T10531- # Support - T10531/1- # Clamping pin - T10531/2- # Turning over tool - 110531/3- # Collar nut -710531/4- Removing: Remove timing chain cover (top) > page 90 Tum vibration damper to "TDC" pe terhold - 710355- 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 vibration damper ~ page 50 Remove lower timing chain cover: Passat CC = page 92 Golf, Eos, Scirocco = page 98 Tiguan = page 105 jon -arrow- using coun- = Remove control valve using assembly tool - T10352- (engine codes CCZA, COZ8, CDA, CDAB: assembly tool - T10352/1-) in -direction of arrow. A Caution The control valve has a left-hand thread. ap AS Ce 114 ep. 18 -cyindr novia gsar -© CC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Remove bolts -arrows- and detach bearing saddle. — Press oil pump chain tensioner in direction of -arrow- and lock in place using locking pin - T4001 = Remove chain tensioner for drive chain -1- — Unscrew bolts -arrows-. 3 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- river with a blade width of approx. 1.5 mm can also be used, LB canon Avoid damage to chain tensioner! Proceed with great :are. Slowly push valve lever - T40243- in -direction of arrow 2- and hold it in that position 1.chaindive 115@ CC 2010 > , Eos 2006 ~ .-Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1%8 and 2.0 | engine, chain drive) - Edition 02. = Secure chain tensioner with locking pin - 148074 Version 2: = Screw in lever - 140243- -arrows-. = Press togetiver retaining ring -1- of chain ter sioner and hold it in that position. — Slowly push lever - 740243- in -direction of aniow-, and hold it in that position. % Secure chain tensioner with locking pin - T40267- All — Remove lever - T4024:-. 116 ep. o-15-Cyindr nad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > , Golf 2009 > , Passat 2006 >... @ ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Bolt camshaft clamp - T40271/2- to cylinder head and insert it in direction of arrow -2- between teeth of sprocket. ifnecessary turn inlet camshaft s:ightly + sing spanner -1-. — Bolt camshaft clamp - T40271/1- te-eylinder head. Brace cam- shaft clockwise -arrow- usiny open-end spanner. = Unscrew bolt -A- and remove tensioning rail while continuing to brace camshaft - «insert camshaft clamp - T40271/1- between teeth of sprocket “2. 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 dive 117@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 — Unscrew bolts -A- and remove guide rail for camshaft timing chain. = Remove camshaft timing chain from camshaft sprockets ands, fitt onto camshaft journals -errows- % = Unscrew bolts -1-. Remove tensioning rail-2-and guide’ alls -3- and -4.. “ N 118 ep. or15-cyindr nad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = 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. Installing + Specified torques = pace 114 = Check if crankshaft is positioned at TDC. The fiat section on crankshaft -artow- must be in horizontal poston. — Using a permanent felt tip marker, make a marking on cylinder block -1=, as shown in illu = Mark tooth -1- of triple chain sprocket whichis aligned with marking -2- using a permanent felt tip marker. — Tum 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 dive 119@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Fitdrive chain for balance shafts. Position chain links with col- ‘oured markings -arrows- at markings on chain sprockets. = Install guide rail ~ ~ Fitcamshatt timing chain onto camshaft journals with coloured ings -arrows- properiy aligned. = Fitrive chain for ol pump onto triple Nin! . = Swing tiple sprocket towarcs efigine (aitectih of arow), and fit it onto crankshaft. The markings -arrows- must align. 120 ep. 0-18 Cyindr nad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 | - Screw clamping pin - T10531/2- into crankshaft, and tighten it by hand, II Fit turning over tool - T10531/3- . Screw on flange nut - 1083%/4-by hand, Slightly move turing over tool back and forth ‘with a 32 mm open-end spanner. While doing so, retighten flange rut until the chain sprocket is securely seated on the crankshaft splines. ?-ow, tighten tensioning bolt -A.. = Position link of drive chain for balance shefts with coloured © marking -arrow- at marking of triple sprocket. Install tensioning © rall-1- and guide rail -2.. Tighten bolts -3- = Make sure that adjustment has been carried out correctly’ ‘chain links with coloured markings -arraws- must be posi- tioned at markings on chain sprockets, 1.chain dive 121@ 6 2010 > , Eos 2008 > , Golf 29041" Golf 2009 > , Passat 2006 > ... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2047. = iccamsivafttiming chain on iniet camshaft, exhaust cams! aft arc: c.aat.shaft. Position chain-links with coloured markings -arrows- at the markings on:chain sprockets. CF me Have a second mechanic hold the exhaust camshaft — Slowy tum exhaust camshaft in direction of arrow -1- until camshaft clamp - T43271/1- can be witherawn from sprocket teeth, = Carefully relieve load on camshaft until camshaft timing chain lies against upper guide rail. Hold camshaft in this position. LX carton Before instaling the whether the col shaft marking ensioning niate it is essential to check chain link is stil aligned with the crank- 122 ep. o-18-Cyindr noad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... @ ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Continue to hold camshaft and install tensioning rail for cam- shaff timing chain. righten bolt -A-. = Remove camshaft clamp - T40271/1- = Slide camshaft clamp - T40271/2- out of sprocket teeth -2-, if necessary turning inlet camshaft slightly using spanner -1-. — Remove camshaft clamp - T40271/2- — Depending on version, remove locking pin - T40011-or locking tool - T40267-. 1.chandive 123@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Check position of coloured chain links relative to markings. = Install chain tensioner -2-. The retaining clip -arrow- must be seated in recess in top section of sump. Tighten bolt -1-, and remove locking pin - T40011- Screw in and tighten bolts -arrows- — Fitbearing saddle carefully. Do not cant bearing saddle! Screw in bolts -arrows- and tighten by hand, = = Tighten bolts -arrows- for bearing saddle > page 111. = Install control vaive = Item 6 (page 112). 124 ep. 18 Cyindr noad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... @ ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Using a 32 mm open-jaw spanner on assembly tool - 710531/3-,, rotate crankshaft 2 full turns in direction of engine fa Note si Dus to the ratio, the coloured hain links do net align with the ‘markings any more after the engine hes been turned. Further assem is bagialy revere of he ismenting 20 sian c 1.9 Assembly overview - drive chain for balance shaft 1- Bott 3 a 9Nm 3 2. Balancer shaft. 2. Renew aftersremoving Q Exhaust side: Lubricate beating with engine oil Removing = page 130 3 - Tube for balancer shaft a Fitting position 7, > page 126 | 4 - Chain tensioner a 85Nm 5- Cylinder block 6 - Balancer shaft 2 Renew after removing Inlet side Lubricate bearing with engine oil Q Removing = page 127 7 - O-ring 2 Lubricate with engine oi! 8 - Locating pin Lubricate with engine oi! Q Fitting position = page 126 1615 14 13 12 1110 9 8 7 6 5 9 - Intermediate shaft sprocket Q For balancer shatt. Ifthe securing bolt has been loosened, the intermediate shaft sprocket must be renewed. 10- Bolt 2 9Nm 14- Washer 12- Securing bolt Ifthe securing bolt has been loosened, the intermediate shaft sprocket must be renewed. 2 Tightening sequence = page 127 1.chandive 125@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 13 - Slide rail For drive chain. 4H - Guide pin 20Nm 15 - Tensioning rail For drive chain. 16 - Guide pin Q 20Nm 17 - Drive chain for balance shafts (Removing and installing = page 127 18 - Chain sprocket 1 Fitting psition > page 113 19- Slide rail For drive chain. 20 - Guide pin 1 20Nm Tube for balancer shaft iétallation position + Lug on tube'fér balance shaft must engage in slot -aiFow. “Bearing mounting - installation position 5+ Renew O-ring -1- and lubricate with oil “Dowel pin -arrow- for bearing mounting must engage in bore in cylinder block Lubricate bearing mounting 126 ep. o-15-Cyindr noad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Chain sprocket - tightening sequence LA cauton The intermediate shaft sprocket must be replaced. Otherwise no tooth backlash is set - engine damage. The new intermed- ate shaft sprocket is coated with a solid film lubricant that wears of afer a short period and thus automatcaly sets the tooth backlash. = Tighten bolt as follows: 1. Prestighten 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. 1.10 Removing and/instailing-drive chain for balance shaft ‘The procedure"Removing and installing drive chain for balarice shaft’ is partof the procedure "Removing and installing camshaft timing chain’ > page 113, 1.14 Removing and installing inlet side bal- ance shaft Special tools and workshop equipment required © Puller -T10394- - Puller “710055- a T1085 1.chaindive 127@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 (G) note The balance shaft must always be renewed after removing. Removing: ~ Remove tootred bett for s00t-iit pump = page 247 = Removes timing chain cover (top) = page 90 ~ Remove lower timing chain cover: Passat CC = page 92 Golf, Eos, Scirocco > page 98 Tiguan = page 105 = Remove camshaft timing chain and dri shaft > page 113 — Remove intermediate gear -1- chain for balance % = Unscrew bolt-2-for inlet camshett balance shaft eh pull out balance shaft 8, If balance shaft cannot be pulled out by hand, use puller - T10394- : — Insert shell half - 110394/1- from puller - T10394- and tums. upwards in direction of arrow. 128 ep. o-15-Cyindr naad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Insert puller - T10394- and push locking collar in -direction of arrow. — Screw puller - T10056- into puller - T10394- and force out bal- ‘ance shaft in -direction of arrow Installing (H) ne Due to the small amount of play between the balance shaft and cylinder block, the balance $i.aft may need to be installed chilled. Sep eda ea block without exerting force. if th:s is not the case the balance shaft must be chilled before installing. Specified torques = page 125 = Place new balance shaft in freezer compartment for 30 mis nutes or spray with commercially available chilling spray. — Lubricate balancer shaft bearing with engine oils" = Install new balancer shaft for inlet camshaft’and tighten bolt 2 — Renew O-ring -1- and lubricate with engine oil — Lubricate bearing mounting with engine oll and insert arrow; bearing mounting must engage in bore in cylinder block. A Caution The intermediate shaft sprocket must be replaced: 0} no tooth backlash is set engine damage. The new i 4 ate sheft sprocket is coated with e solid fim lubricant that wears. off after @ short period and thus automatically sets the tooth backlash. 1.chain dive 129@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 >... -cyl. imection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Mark faces of gear teetn of idler gear with paint -arro.vs. — Insert inter eulate gear; marking on baince shart must be positioned between markings on taces ot gear teeth, = ligasten bolt for sprocket -1-: tightening sequence = page 127 = Check markings on intermediate shatt eprocket/balancer shaft -arrow- Due to the ratio, the markings align only after every 7th turn. = Install drive chain for balance shaft and camshaft timing chain = page 119. - The remaining installation steps are carried cut in theeverse se- quence. Note the following: — Renew cil seal for coolant cump drive = page 249. 1.12 Removing and installing exhaust side balance shaft 2 ‘Special tools and workshop equipment required Puller - T10394- & 130 pep. or15-cyindr noad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 > Puller -T1005.- The balance shaft must always be renewed after removing. 2 Removing: 3 = Remove timing chain cover (top; > page 20 : = Remove lower timing chain cover: Passat CC = page 92 _Golf, Eos, Scirocco = page 98 “Tiguan = page 105 — Remove camshaft timing chairffpd drive chain'for balance shaft = ms — Unscrew bolt ° iid pull out baldhice shart If balance shaft cannot be pulled out by hand, use puller - T10394- : oN BY an Poi — Insert shell half -110394/1- from puller - T10394- 1.chain dive 131@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy injection engine (1.8 and 2.0 | engine, chain drive} - Edition 02.2017 = insert putler - T10394- ana push loc “arrection of arrow. 1g coller in — Screw puller -10055- into puller - T10394- and force out bal- ance shaft i Installing: (Hm Due to the small amount of play between the balance shaft and cylinder block, the balance shaft may need to be installed chilled. Pa eae ro re pe block without exerting force. If this is not the case, the balance shaft must be chilled before installing. 3 + Specified toryues = page 125 = ~ Check installation position of tube for balancer shatt -errow- The lug-arrow- must be on top. Itfunctions as ar anti-twist device. (@ note % To get the tube nto installation position, it must be Squeezed to- gether sight. Insert 2-hole pin wrench - 3212- in front bores of {ube and press together. Then Insert plpe with Z-hole pirswrench = Place new balance shaft in freezer compartment for 36 mi- nutes or spray with commercially available chilling spray. = Lubricate balancer shaft bearing with engine oll — Install balance shaft for e page 138 5- Cylinder head 2 Removing and installing = page 140 Check for distortion = page 138 Renew oi! 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 Lubricate with engine oil 8- Plugs a 5Nm 2.oyindertoad 1354-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 With ball head for engine cover panel 9-Cap With seal 40 - O-ring O Renew Lubricate with engine oil 41 - Plugs 12- Holder 13 - Bolt a 8Nm 414 - Heat shield 15-Solt @ 20Nm 16 - Solt @ 20Nm 17- To intake hose/turbocharger 16 - Breather pipe 19 - O-ring No replacement part 20- Seal s No replacement pat 21 - Motor cover 22 Bott O Selt-tapping Tightening sequence = page 137 23 - Crankcase ventilation Note correct sequence when tightening = page 137 24 - To intake manifold 25 - Seal Renew if camaged 26 - Seal O Renew 27 ~ Vacuum pump Removing and installing = pace 178 28 - Sectiring bolts for vacuum pump Engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA:9. Nm 1D _Enginé:codes CCZA, CCZB, COZC, COZD, CDAA, CDAB: 8 Nm # additional 180° turn Renew after removal 29-9Nm. a Only engine code CBFA, 30 - Secondary air inlet valve - N112- Only engine code CBFA Removing and installing > page S50 31 - Seal Only engine code CBFA 136 Rep. o.15- cytindsr head, valve gearALcyl. injection engine (1.3 and 2.0 | engine, chain drive - Edition 02.2017 a Renew 32- Retaining plate 33 - Bolt 2 Nm 34 - Union 2 Engine code CBFA: before removal, secondery air inlet valve - N112- must be removed = page 550 35 - O-ring Q Renew Lubricate witn coolant 36 - Bolt 2 25Nm yrs" 37 - Transportation ‘shackle 38-Bolt a 9 Nth 39- Hall sender - G40- 40 - Pattition Crankcase breather system - tightening torque = Tighten bolts for crankease breather in the sequence Ae. 10-to14. Nm. Loosening ¢ylinder head bolts © Ifthe cylinder head bolts havé multi,oiit Sdckets and a shout. der, the camshafts must be -emoved before the cylinde: head’ bolts are unscrewed. Ifa cylinder head cover without sealing pluys for the cylinder head bolts -6- is installed, the camshafts nuist be removed. = Unscrew bolts -arrows-. = Slacken cylinder head bolts in the sequence -1 2.0yindertoad 1374-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 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+ Tum 90° further using rigid wrench 3- Turn 90° further using rigid wrench — Then tighten bolts -arrows-. 1. Prectighten bolts to 8 Nm so.voitevane 2+ Tur bolts 90° further using iid wrench n Cylinder head - tightening sequence, camshaft removed =. Tighten cylingér head bolts in the sequence -41 ... 10- as fol- lows: s 1+ Tighteinitialy to 40 Nm using torque wrench 2- Tum 80° further using rigid wrench 3- Tum 90° further using rigid wrench = Thenilighten bolts -errows- 1 Prestighten bolts to 8 Nm 2+ Tum bolts 90° further using rigid wrench ‘Checking cylinder head for distortion ~ Use straight ecige 500 mm - VAS 6075- and feeler gauge to measute cylinder head for distortion at several points # Max. peffissible distortion: 0.05 mm. 22 Renewing oil non-return valve in cylin der head ‘Special tools and workshop equipment required # Hooks e.g. assembly tool -T10118- T10118 ao 138 pep. o-15-cyindr haat, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Removing — Remove cylinder head > page 140. = Pullout oil non-return valve -arrow- with a suitable hook, e.g. assembly tool - T10118- s Installing = Clean oll channels. — Mbisten seal for new oil non-return valve with clean engine oil = Insert oll non-return valve by hand into‘cylinder head to stop. = Install cylinder head = page 140 23 Removing and installing engine cover Removing — Pull engine cover panel off upwards at securing points “arrows Installing — When fitting, make sure that rubber butters are correctly in- serted in mountings. = Press engine cover panel back carefully into its retainers, — Toprevent damage, do not strike engine cover panel with the fist or a tool. 2.0yindertoad 139CC 2010.» Eos 2006 > , Golf 2004 > , Golf 2009 *°, Passat 2006 >... 4-cy1 injection engine (1.8 and 2.0 | engine, chain drive) ~‘Edition 02.2017 2.4 “Removing and installing cylinder Head (G) Note ifthe cylinder head bolts have mult-point sockets anda shou!- der, the camshafts must be removed before the cylinder head bolts are unscrewed. Ifoylinder head bolts vith a multipoint socket head and shout der are used for installation, the cylinder head bolts must be inserted beiore the camshafts are installed. + /fa cylinder head cover without sealing plugs for the cylinder ‘nead bolts -5 is or is going tobe installed, the camshafts must be removed. Checking guide rail version: (G) note Depenaing on the respective repair work to bageprried out and on the version of the guidé'rail, diferent proceddtgs apply. Pleése check. which guide rail is installed before starting work = Remove timing chain cover (top) = pace 90 = Check guide rail -1- in area indicated by -arrow. A= Long guide rail B - Short guide rail Removing cylinder head, ita »shorte guide rail is installed and the camshaft timing chain shell remain installed: Procedure 22.4.1 Removing and installing cylinder head”. page 140 [ Ee) Removing cylinder head, ifa »shorte 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 firing chain’, page 163. Removing cylinder head, if a »longe guide rail is installed: Procedure 2°24. installing cylin {iming chain’, page 163 2.4.1. Removing and installing cylinder head 140 Rep. 0.18 cytindsr head, valve gear. © Eng tees CC 2010 > , Eos 2006 > ‘Special tools and workshop equipment required Assembly tool - T10352- ine codes CCZA, CczB, Cczc, CCz0, CDAA, CDAB: assembly tool - 140352/1- Counterhold tool - 110355- Locking pin - T40011- Assembly lever - T40243- Locking tool - 140267- Camshatt clamp - 740271- Golf 2004 > ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Golf 2009 > , Passat 2006 > , 2.0yinderead 1441+ Torque wrench - VAG 1331- V.A.G 1331 # Torque wrench -V.AG 1332. Workshop hoist - VAS. 6100- # Engine plug set - VAS 6122. + . Drip tray for workshop hoist ~ VAS €208- Polydrive cylinder head bolts: Special wrench, long | VAS 6100, reach - T10070- Cylinder head bolts with miutt-point socket: Mutti- point socket 12 mm + + VAS 6208 Lifting tackle - 2024 A. CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 V.A.G 1332 Qe VAS 6122 geet Ss ° pee. 710070 > a 142 Rep. o:.18- cylinder head, valve gearCC 2010 > , Eos 2006 ~ , Golf 2004 > . Golf 2009 > , Passat 2006 ~ , ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 @ Holder -T10014- T 10014 Puller - T40039- 740039 Removing: Fit cable ties in the original positions when installing. @ Always seal open channels of the intake and exhaust systems with suitable plugs. For example, those from engine bung set = VAS 6122- = Pull off engine cover panel + page 139 =. Remove air filter housing > page 459 a 2.0yindertoad 1434-c', injection engine 1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Release hese clip -2-. — Unscrew bolt -4-. — Lisconnect eiectr.cal 20,,nector -arrow- and move electrical wires clear. ZY venue Danger of scalding due to steam and hot coolant. On @ 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 filer cap on expansion tank. ~ Remove front exhaust pipe with catalytic converter: Passat, CC = page 517 Golf, Eos, Scirocco = page 533 Tiguan = page 543, AG. Vokonage ~ Remove front right wheel: ~ Remove noise insulation = General body repairs, exterior; Rep. yr. 50; Noise insulation — Remove right wheel housing liner = General body repairs, exterior, Rep. gr. 86 ; Whee! housing liner — Drain cgolant = page 235. — Remove charge air hose -A.. - Remove bolt -1- and take out air pipe downwards. 144 ep. o-18-cyindr naad, vate gsarCC 2010 > , Eos 2006 ~ , Golf 2004 > , Golf 2009 > , Passat 2006 >... (@) chain drive) - Edition 02.2017 4-oyl. injection engine (1.8 and 2.0 lengine. — Remove bolts -arrows- — Remove air pipe (lit clips -items 1 and 2.) Separate electrical wiring connections -1 and 2- and place ‘electrical wiring to one side -arrows-, é Vehicles with seat heating! — Unscrew bolts -1 and.2- and move coolant pipes to the left. Vehicles with all-wheel drive — Remove right drive shaft > Running gear, axles, steering: Rep. gr. 40 ; Removing and installing drive shafts . All vehicles: = Remove bolts -1 and 2- and detach support for turbocharger. 2.0yindertoad 145@ CC 2010 > , Eos 2006»: Golf 2004 > , Golf 2009 +, Passat 2006 > , ... 4-cyl. injection enginé (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Remove banio bolt#2- and move coolant pipe clear to one side. Vehicles with front-wheel drive: — Remove bolts -1- on oil return line Vehicles with allawhee! drive: = Remove bolts of oil return line at crankcase, All vehicles: = Removetott-3-on all supply ine, = Only vebicles with sound generator: Remove charge air duct to sound generator. — Pull connector -1- off camshaft control valve 4 - N205- = 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. 146 kop. o-15-cyindr nad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Disconnect crankcase breather hose -1-. — Remove bolts -arrows- and remove crankcase breather. © Engine codes CBFA, CCTA, CCTB: 2 = Disconnect crankcase breather hose -1-. = Unscrew bolts -arrows-. ‘=, Unscrew bolt -arrow- for air pipe, ~ “Loosen hose clip -1- and remove air pipe together with eran case breather. $ All A 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 2.0yindertoad 147@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 > . 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Disconnect coolant line to coolant expansion tank arrow — Remove coolant hoses -arrows- from coolant pipe, ~ Unbolt earth cable -3- and loosen bolt -4-, = Pull off vacuum hoses -arrows-. Unscrew bolts -1...3- and remove heat shield together with coolant pipe. = Unscrew oil supply line -4- from turbocharger. 148 Rep. o:.15- cylinder nead, vave gearALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 [&) Note Unscrew bolt -2- from heat shield using a 6 mm hex key -A.. The hexagon faces must be at least 8 cm long -B.. A socket which tapers to 5 mm at the tip is too thick. C10 Pull off electrical connector -2- from fuel pressure regulating valve N276- Engine code CBFA: ~ Pulleonnector-A- and heee.-B. from secondery ar init valve, , Eos 2006 > , Golf 2004 > sGeif 2009 > , Passat 2006 >... 4-cyi. injection engine (1.8.and 2.0 | engine, chain drive) - Edition 02.2017”. All — Pull coolant hose from union on sid of cylinder head. = Separate elect ical connectors -F'to 4. ~ Place electrical cable 5 to oné side. = Pulloff .ccuum line 8 leeding to actveted chercoa iter Golf, Scirocco: =. Pull off breather line -1-, release activated charcoal filter -A- and remove upv'erds -B-. All = Separate electrical connectors -1- and pull out connectors from retainer. — Separate electrical connectors -2 to 4. Unscrew bolts -arrows- and detach coolant pipes from intake manifold. ee | 150 ep. or18-cyindr noad, vate gsarSC 2010 ~ , £32006 ~ , Golf 2004 > , Golf 2009 > , Passat 2006 >... (@) 4-oy1. injection engine (118 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Remoie intake manifold support (remove securing nut bal2) = -Removing oil fiter and = Disconnect coolant hoses -arrows- and move clear, — Unscrew bolts -arrows- and remove inlet camshaft control valve 1 - N205- - Remove timing chain cover (top) = page 0. A Caution The control valve has a leftchand thread = Remove control valve using assembly tool - T10352- (engine codes CCZA, CCZB. CDAA, CDAB: assembly tool - 710352/1- ) in -direction of arrow.. rfl 2.oyindertead 151@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. iection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Remove bolts -a/rows- and detach bearing saddle Tum vibration dé temnoldT10355- + Notch on vibration deuper must align with arrow marxing on cover ior timiny chains (bottom). + The markings -1- on the camsha'ts must ace upwards, F fo “TDC" position -arrow- using coun- ~ Mark positi6ns of sprocket markings -1- on camshaft timing chain and cylinder head -arrows- Using @ permanent fet tip, marker - Also mark alignmentiof camshaft timing chain, guide ral of camahatt timing chain Using pe marker rs ue ~ Remove sealing plug -arrow-. 152 pep. o18-Cyindr noad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Unscrew kolts -arrows- = Unscrew bolt «arrow. Depending on version, elther of two different chain tensioners may be installed. Version 1 = Screw in lever - 740243. -arrows-. = + fits not possible to insert the lever - T40243-, the distance between the timing chain atid the of defector on the lower ‘cover is too small is then necessary 1 remove the lower cover. : © Passat CC = page 92 © Golf, Eos, Scirocco = page 98 © Tiguan > page 105 Raise locking element of chain tensioner -arrow 1-. To do this, {ing the tip ofthe locking pin - T40011- to a point A screw, river with a blade width of approx. 1.6 mm can also be used. A\ casion Avoid damage to chain tensioner! Proceed with great care. — Slowiy push valve lever - 740243- in -direction of arrow 2- and hold it in that position 2.oyindertead 153@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 » ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Secure chan tensioner with locking pin - T40011- Version 2: = Screw in lever - 740243- -arrows-. (@ note + ifitis not possible to insert the lever - T40243-; the disiance between the timing chain and the oil deflector on the love," 0,2" is too small Itis then necessary to rernove the lower cover. = # Passat, CC.= page 92 + Golf, Eos, Scirocco = page 98 @ Tiguan 2 page 105 = Press together securing clio -arrow- of chain tensioner. Then, ‘slowly push lever - T40243- in -direction oi arrow- and hold it in tnat postion = Secure chain tensioner with locking pin - 740267 Continued for ail — Remove lever - T40243- . 154 pep. o-18-Cyindr noad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 — Bolt camsauft clamp - T40271/2- to cylinder head and insert it indirection of arrow -2- between teeth of sprocket. Ifnecessary tuin inlet camshaft in direction of arrow -1- using spanner. — Bolt camshatt clamp - T40271/1- to cylinder head. Counter- hold camshaft clockwise -arrow- using 0, en-end spanner. - Remove bolt -A- and take out tensioning rail downwards. In the process, continue to counterhold the camshait. — Tum exhaust camshaft clockwise -1- until camshaft clamp - 4027 1/1- can be inserted into sprocket splines -2- 2.oyindertead 155@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = 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, A Caution Avoid damage to valves and piston crowns. ¢ Do nut tum the crankshaft after the camshaft timirg chain has been removed from the cylinder head. = Ifa cylinder head cover without sealing plugs for the cylinder head bolts -5- is installed, remove the camshafts of 204 5 3 = page 183. ° = Ifacylinder head cover with sealing plugs forall eyiinder head bolts is installed, turn sealing plugs -arrows- anti-clockwise in, direction of -arrow- by 90° and remove. = Unscrew ball head -1 ... 2. 4S = Remove filler cap. ‘Mult-point socket head bolt with shoulder: - Remove camshafts = page 183, = Unscrew bolts -arrows- = Unscrew and remove cylinder head bolts in the sequence “Ato 10- 156 pep. or18-cyindr haat, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Polydrive bolts: — Unscrew koltsYarrows-. — Unscrew cylinder head bolts using polydrive bit afid. socket - T10070- in sequence ~1 to 5-. [Bnew ¢ Make sure all hoses/pipes and wiring are removed. 4 © Ensure tensioning rail and guide reil are not damaged when Iittng off cylinder head. = Remove cylinder head. = Place cylinder head onto soft surface (foam plastic) 3 Install cylinder head > page 160 If the camshafis are renewed, the markings which you applied earlier must be transferred. To do so, proceed as follows: — Mark alignment of camshaft sprockets relative to camshaft clamp - 40271/1- and camshaft clamp - T40271/2- on re- moved cylinder head -arrow-. (Baws net ales es whether the markings have been ty transferred. — Measure distance from left outer edge of web -A- to marking -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. 2.0yindertoad 157@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Tum inlet camshatt in direction of arrow -1- using spanner, slide camshatt clamp - T40271/2- from between teeth of sprocket -2-and move camshaft into rest position. = Remove camshaft clamp - T40271/2- ~ Turn exhaust camshaft in direction of arrow -1- using spanner, slide camshaft clamp - T4027 1/1- from between teeth of, sprocket -2-and move camshaft into rest position. — Remove camshaft clamp - T40274/1- markings applied when removing, Now complete cylinder héad which is o be installed and a 158 pep. o-18-cyindr naad, vate gsar-Lcyl. injection engine (1 atid 2:0'-engine, chain drive) - Edition 02.2017 Bolt camshaft clanp - 1402722 to uylinder head to te instal- = T.-ninlet samshaft in direction of arrow -1-:ntii marking -3- aligns with camshatticlamp - 74027 1/2- Insert camsnatt clamp - 742271/2- into teeth of sprocket -2- — Compare distancé from left outer edge of web -A- to marking -B- with figure recorded earlier. ~ Bolt camshaft clamp - 140271/1- to cylinder head. — Tum exhaust camshaft in direction of arrow -1- until marking -3- aligns with camshaft clamp - T4927 1/1- — Insert camshaft clamp - 740271/1- into teeth of sprocket -2-. 2.0yindertoad 159CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Compare distance from marking on inlet camshaft -B- to mark- ing on exhaust camshaft -C- with figure recorded earlier. Installing cylinder head: + Specified torques = page 135 LY 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. # No oil or coolantyntist be allowed to remain'in the bind holes ‘or the.tylinder head bolts in the cylinder block. Ensure thatéylinder head gasket seals properly: Carefully remove remains of emery and abrasives. ¢ Donot remove new cylinder head gasket from packaging until itis ready to be fitted. ¢ Handle the ‘head gasket ‘carefully to prevent daraga 0 Maaicone coving ortho hand arta oF e asker Avoid damage to open valves. When instaling an exchange cylinder head, the plastic ‘protectors fitted to protect the open valves should not be 3 removed until the cylinder head is ready to be fitted. Avoid damage to valves and piston crowns after werking on valve gear. ¢ Tum the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is op- é ‘erated. a) Note: # Renew botts lihich must be tightened iffier toa torque’ angle. # Renewseltlocking iiuts.as wellas gaskets, seals and O-rings. 4% Wihen installing @ exchange cylinder head, the contact surfa- ces between hydraulic compensation elements, roller rocker fingers and cams must be oiled before instaling 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 4s original equipment = Electronic parts catalogue % inorder to be ina position to securely attach the charge air ‘hoses on thelr connections, the worm screws of the used hose clips have to the sprayed with penetrating spray before insta fing. 160 Rep. o:.15- cytindsr nead, valve gearCC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 > , @ ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = 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. BZ cauion When turing the crankshaft, pull the timing chain upwards until taut 50 that it does not become jammed. — If crankshaft has since been tumed, position cylinder number 1 piston to TDC and then turn crankshaft back slightly = Fitoylinder head, — Insert cylinder head bolts, and tighten them by hang. ~ Tighten cylinder head: Tightening sequence = Fig. “Cylinder head - tightening sequence, camshaft instal- ied™ page 138 Tightening sequence ‘Cylinder head - tightening sequence, camshaft re- — Install camshatts if removed = page 183 L\ cauton When tuming the crankshet pull the timing chain upwards until taut so that it does not become jammed: - Tum vibration damper to*TDC" position -arrow- using coun- terhold - 710355- + Notch on vibrationdamper must align with arrow marking on cover for timing chains (bottom) Fit camshaff-timing chain on sprockets. To do this, align mark- ings on chain links -arrows- with markings on sprockets -1-. = Install upper guide rai (B note Have a second mechanic hold the exhaust camshaft. a 2.0yindertead 161CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Slowly turn exhaust camshaft in direction of arrow -1- until camshaft clamp - T40271/1- can be withcrewn from sprocket teeth -2.. = Carefully relieve load on camshaft until camshaft timing chain lies against upper guide rail. Hold camshaft in this position = Continue to hold camshaft and install tensioning rail for cam- shaft timing chain. Tighten bolt -A. - Remove camshaft clamp - T40271/1- — Slide camshaft clamp - 740271/2- out of sprocket teeth - necessary turing inlet camshaft slightly using spanner ~ = Remove'camshaft clamp - T40271/2- 162 ep. or18-cyindr noad, vait'gaarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Check markings. Markings on camshaft timing chain and cyl- inder head -arrows- must align with markings on sprockets = Markings on camshaft timing chain and on guide rail of car- 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! Screw in bolts -arrows- and tighten by hand. = Tighten bolts -arrows- for bearing saddle = page 111 = Depending on version, remove locking pins Ta00 Tt ariodkiay'Su tool -T40267- = Screw in bolt -arrow-. = Install control valve = Item 6 (page 112) Now continue installing in reverse order of removal, observing the following: 5 = Change engine oil. = Add coolant = page 235 2.4.2 Removing and installin, qr camshaft timing chain 2.0yindertoad 163CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Special tools and workshop equipment required # Assembly tool - T10352- # Engine codes CCZA, CCzB, CCZC, CCZ0, CDAA, CDAB: assembly tool - T40352/1- Counterhold tool - 710355- Locking pin - T40011- Assembly lever - 140243- Locking tool - 140267- Camshaft clamp - T40271- toeee 164 Rep. o.18- cytindr head, valve gearCC 2010 > , Eos 2006 ~ , Golf 2004 > . Golf 2009 > , Passat 2006 ~ , ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Torque wrench - VAG 1331- V.A.G 1334 VAG 1332 @ Torque wrench -V.AG 1332. ¢ Workshop hoist - VAS 6100- @ Engine plug set - VAS 6122. SS 9) eee . Drip tray for workshop hoist PVAS 6208. ° Polydrive cylinder head bolts: Special wrench, long VAS 6122 reach - T10070- Cylinder head bélts with multi-point socket: Multi- point Socket 12 mm . - VAS 6208 710070 Lifting tackle - 2024 A. 2.oyindertead 165Puller - T40039- Removing: {i Note 4 Botore the cylinder head is removed, the engine support and engine mounting must oe reinstalled temporary, because the eyes of the suppor bracket are secured to the éylinder head. + Fit the cable ties in the original position when instaling. 4 Sealopen channels ofiqlake and exhaust system with suitable lugs from engine bung set- VAS 6122-. = Pull off engine cover panél = page 139 = Remove air fiter housing = page 459 = Release hose clip -2-. = Unscrew bolt -4- % = Disconnect electrical connector -arfow- and move electrical wires clear. A wane 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 filer cap on expansion tank. — Remove front exhaust pipe with catalytic converter: Passat, CC > page 517 Golf, Eos, Scirocco = page 533 Tiguan = page 543 — Remove front right wheel = Remove noise insulation + General body repairs, exterior, Rep. gr. 50 ; Noise insulation = Remove right wheel housing liner > General body repairs, exterior, Rep. gr. 66 : Wheel housing liner — Drain coolant = page 235. CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 40039 166 Rep. o.15- cytindsr head, valve gsar@ CC 2010 > , Eos 2006 ~ . Golf 2004 ~ . Golf 2009 > , Passat 2006 ~ 4:ayfcinjection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ve charge air hose -A-. — Remove bolt -1- and take out air pipe downwards. Q : 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-. 2.0yindertoad 167@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Vehicles with seat heating: — Unscrew bolts -1 and 2- and move coolant pipes to the left Vehicles with all-wheel drive: ~ Remove right drive shaft = Running gear, axles, steering: Rep. gf. 40; Removing and installing drive shafts All vehicles: set ‘AG = Remove bolts Remove banjo bolt -2- and move coolant pipe clear to one side. icles with front-wheel drive: = “Remove bolts -1- on oil return line Vehicles with all-wheel drive: — Remove bolts of oil return line at crankcase, All vehices: ~ Remove bolt -2- on oll supply line. 168 ep. o-15-cyindr noad, vate gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 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 airbipe. = Remove sir pipe, loosening hose clip -1- to do so. ind pull crankcase breather off air ' 3 3 f hose. é = Disconnect crankcase breather hose -1-. — Remove bolts -arrows- and remove crankcase breather. Engine codes CBFA, CCTA, CCTB: — Disconnect crankcase breather hos — Unscrew bolts -arrows-. 2.0yindertoad 169@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Unscrew bolt -arrow- for air pipe. — Loosen hose clip -1- and remove air pipe together with erank- case breather. Ally LX wanne |: 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. = Détach lines -1 to 3-from the fuel transfer point. 1) Breather hose 2) Vactium line (only CBFA, CCTA, CCTB) 3) Fuel supbly,jine = Disconnect coolant ltie to.coolant expansion tah -arrow- -arrows- from coolant pipe. and loosen bolt -4. Remove coolant hose: = Unbott earth cable 170 ep. 18 -Cyindr nad, vate gsarCC 2010 > . Es 2006 ~ . Golf 2004 ~ . Golf 2009 ~ Passat 2006 > , @ Acyl. injedtion engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Pull off vacuum hoses -arraivs- — Unscrew bolts -1...3-and remove heat shield together with coolant pipe. = Unscrew oil supply line-4- from turbocharger. (B) 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- 2.0yindertead 171@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edi Engine code CBFA: ~ Pull connector -A- and hose -: from secondary ar inet valve — Loosen coolant pipe by unscrewing bolts -arrows-. = Pull coolant hose from union on side of cylinder head, — Separate electrical connectors -1 to 4. = Expose electric cable -5. — Pull off vacuum line -6- leading to activated charcoal fiter. Golf, Scirocco: = Pull off breather ling and remove upwards -B- release activated charcoal filter -A- 172. ep. 0.18 -Cyindr naa, vale gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 All — Disconnect electrical connectors -1- and detach connectors from retainer. — Separate electrical connectors -2 to 4-. - Unscrew bolts -arrows- and detach coolant pipes from intake manifold, ~ Remove intake manta /suppért (remove securing nut-1- and ito = Removing oil fiter é = Disconnect coolant hoses -arrows- and move clear. = Remove camshaft timing chain > page 113 — Reinstall engine support and-engine mounting, and tighten bolts by hand, ~ Detach spindles of support brackét 2.0yindertoad 173CC 2010 1's 2006 > , Golf 2004 >": Golf 2009 > , Passat 2008 > ... 4-cyl, injection engine (1.8 and 2.0 | engine, chain.crive) - Edition 02.2017 ~ Ifa cylifider head cover without sealing plugs for the cylinde?:, head bolt installed, remove the camshafts = Ifa cylinder head cover with sealing plugs for all cylinder head © bolts is installed, turn sealing plugs -arrows- anti-clockwise in = direction of -arrow- by 90° and remove. = “Unscrew ball head 1... 2- = Remove filler cap ‘Mult-point socket head bolt with shoulder: - Remove camshafts = page 183. = Unscrew bolts -arrows- — Unscrew and remove cylinder head bolts in the sequence =A to 10- a 174 ep. o:18-Cyindr nad, vale gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Polydrive bolts: — Unscrew bolts -arrows-. — Unscrew cylinder head bolts using polydrive bit and socket - T10070- in sequence ~1 to 5-. Make suré all hoses/pives and wiring are removed. ~ Remove cylinder head. + Place cylinder head onto soft surface (foam plastic) Installing cylinder head: + Specified torques > page 135 [F] Note © Replace bolts that are tightened with specified tightening an- gee @ Renew gaskets, oil seals and self-locking nuts. ¢ Hose connections and air duct pipes must be free of oi! and grease before assembly. ¢ Secure all hase connections with the correct type of hose clips ‘same as original equipment) > Electronic parts catalogue ©. Spray the worm screws ofthe used hose clios with penetrating “spray before installing. = Do not remove new cylinder head’geket from packaging until iis ready to be fited. The sicongoating an the indented area of the cylinder head gasket Malst not be damaged. = Carefully remove séélant residue from cylinder head and cyl- inder block. Ensure that no long scares or scratches ere made ‘on the surfaces, while doing 80. Carefully remove remains of emery and abrasives. Clean blind holes for cylinder head bolts. Blow out with com- pressed air if necessary. 2.0yindertoad 1754-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Position cylinder head gasket. Note centring pins in cylinder block -arrows-. 4 Check installation position of cylinder head gasket. Charac- teristic: the part number should be legible from the inlet side. ~ If crankshaft has since been tumed, position cylinder number 1 piston to TDC and then turn crankshaft back slightly. = Fiteylinder head, =. Insert cylinder head bolts, and tighten them by hand. = Tighten cylinder head: Tightening sequence = Fig. “Cylinder head - tightening sequence, camshaft instal- ied” page 138 Tightening sequence > Fig. "'Cyiinder head - tightening sequence, camshaft moved™. page 136 — Using support bracket - 10 - 222 A-, support engine in instal- lation position again, 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 cil = Maintenance ; Booklet ; Engine oil Draining; Renewing oil fter and replenishing engine oll = Fill with new coolant = page 235 . 25 Checking compression 176 Rep. o.15- cytinds head, valve gearCC 2010 > , Eos 2006 ~ . Golf 2004 » . Golf 2009 > , Passat 2006 > , ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ‘Special tools and workshop equipment required © Spark plug socket end ex. tension - 3122 B- Puller -740039- @ Torque wrench - V.AG 1331- ¢ Compression tester-V.AG 1763- © Adapter - V.A.G 1381/54 # Adapter-V.AG 1381/1- | ya a agar SS) Test sequence (B) note © Observe all relevant safety precautions = page 552 %@ Engine oll temperature min. 30 °C © Battery voltege at least 12.7V Proceéd as follows: = Pull cheng coe ae aa — Removing ignition coils with outputstages >.page 553 - Unscrew spark plugs Using spark pig socket - 3122 B- 2.0yindertoad 1774-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Check compression using compression tester - V.A.G 1763- adapter - VAG 1381/1- and adapter - VAG 1381/54. V.A.G1985A -V.A.G-1763 @) Note Using compression tester: > Operating instructions = Start engine until tester shows no further pressure increase. Compression pressures: VAG 1381/1 New bar pressure | Wear limit bar pres-| Difference between fa) ‘sure cylinders bar pres- ‘sure: 14.0 to 14.0 70 max. 3.0 = Install spark plugs, specified torque = page 563 = Install ignition coils with output stages > page 553, Faults wil have been stored in the memory because connectors ‘have been disconnected. Read and, ifnecessary, clear the event memory after the test. — Read event memory of engine control unit > vehicle diagnos- tic tester Removing: Proceed as follows: = Remove motor cover panel > page 139 = Remove alr fiter > page 459 - Remove high-pressure pump with »roller tappet« > page 483 = Unbolt earth cable -3- and remove bolt -4-. 26 Removing.and installing i =e 178 Rep. o.18- cytinds head, valve gearALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 - Remove vacuum hose -1- from vacuum pump. im The vacuum pump must not be dismantled. isang: © Speciied torques = page 135 Perform assembly in reverse order of removal, observing the fol- lawing: — “Clean sealing surfaces, = Position gasket on vacuum pump, insert 2 bolts and then po- sition on cylinder head. ray he 2.0yindertoad 1794-cyi. injection engine (1.8 and2.0-'engineschain drive) - Edition 02.2017 3 Valve gear w Note + Cylinder head and cylinder head cover must be renewed to- a gether: + After installing camshafts wait for aporox. 30 minutes before Starting engine. The hydraulic compensation elements must settle (otherwise valves will strike pistons). After working on the valve gear, turn the engine carefully at ‘east 2 rotations fo ensure that none of the valves make con- tact yihen the starter is operated. 3 + Amays renew gaskets and seals. Assembly overview - valve gear > page 180 Removing-and installing camshafts = page 183 Checking axial clearance of camshefts = page 198 Renewing vaive stem seals > page 198 Checking valve gtides = page 202 3. Assembly overview - valve ee 180 Rep. o.15- cytindsr nead, valve gsarCC 2010 > , Eos 2006 ~ . Golf 2004 > . Golf 2009 > , Passat 2006 >... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 1- Outlet valve @ Donot rework. Only lap- Ping in is permitted, Valve dimensions Checking valve guides = page 202 2- Cylinder head Renew oil non-return valve in cylinder head = page 138 3- Valve guide Checking > page 202 4- Valve stem seal 5- Valve springs 6 - Valve epring plate 7 - Cotters 8- Hydraulic compensation el- ‘ement 2 De not interchange 2 Oil contact surfaces. 9- Exhaust camshaft Check radial clearance with Plastigage (roller rocker fingers removed) Radial clearance with bearing 7 of 24 mm: 0.024 ... 0.066 mm Q Radial clearance with bearing @ of 32mm: 0.030 -.. 0.054 mm 2 Runout: max. 0.04 mm 2 Removing and installing = page 183, 10- Cylinder head cover With integrated camshatt bearings. Clean sealing surface; reworking not permitted, Remove sealant residue, 14- Bolt a Renew. 2 Tightening sequence = page 182 12- O-ring a Renew 2 Lubricate with engine oil 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 Removing and installing = page 183, 8.vaveoser 1814-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 15-Cap Q Renew G_ 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 a Do not rework. Only lapping in is permitted, =" K Valve dimensions = page 182 Checking valve guides = page 202 Tightening sequence for cylinder head cover Renew bolts, 1. Fitbolts in the sequence -1 ... 6-and hand-tighten in several stages. 2. Tighten bolts in the sequence -1 ... 6- to 8 Nm using torque wrench, 3. Turn 90° further in the sequence -1 ... 6- using a fixed, wrench, (E) now ° Take care to keep retaining frame straight. Valve dimensions [B) me Inlet and exhaust valves must not be reworked, Only lapping-in ispernitied. [Dimension ‘niet valve Outiet valve Ba mm| 33.854 0.10 28.0401 ob mm| 5.98 + 0.007 5.955 + 0.007 ec mm 103.97 101.87 ja é 45 45 182 ep. 0-18 Cyindr noad, vale gsarCC 2010 > , Eos 2006 ~ , Golf 2004 > . Golf 2009 > , Passat 2006 ~ , ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 3.2 Removing and installing camshaft Special tools and workshop equipment required © Assembly tool - T1035 @ Engne cudes COZA, CCzB, CCZC, CCZD, CDAA, CDAB: assembly tool - 110352/1- Counterhole! ool - T40355- Locking pin - T40011- Assembly lever - T40243- Locking tool - T40267- Camshaft lamp - T40271- toe ee © Press tool - T10174- S 8.vawocer 183CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Puller - T40039- 40039 + Slicone sealent-D 154 103,A1- (B) re 5 ¢ =Sealing surfaces at bottom of cylinder head cover and top of eyinder head must not be machiged. % The camshaft bearings are inte,y ated into the .ylinder head and cylinder head cover. The camshaft tining chain must be reieved of tension before yo. remove the cyiinder head cover. + Renew sealing cap if cylinder head covér has been detached SMtom 15 (page 122) a Fit cable ties in the original positions when installing, Removing: — Pull of engine cover panel > page 139 - Remove vacuum pump > page 178 = Remove noise insulation > General body repairs, exterior Rep. gr. 66; Noise insulation; Assembly overview ~ noise in- sulation - Remove right wheel housing liner > General body repairs, exterior, Rep. gt. 66 : Wheel housing liner, Removing and) installing wheel housing liner Remove bolts -arrows- Remove air pipe (lit clips -tems 1 and 2.) 184 Rep. o:.18- cylinder nead, valve gsarNGO: Wa en CC 2010 =" Eos 2006 ~ . Golf 2004 > , Golf 2008. , Passat 2006 > ... (@) Acyl. ifijection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 ~ Detach connector -1- fram camshaft control valve 4 - N205- — Unscrew bolts -arrows- and remove inlet camshaft control valve 1=N205-. — Remove upper timing chain cover = page 90. — Remove control valve using assembly tool -710352- (engine codes CCZA, CCZB, CDAA, CDAB: assembly tool -| 710352/1- ) in -direction of arrow, A Caution The control valve has a left-hand thread. — Remove bolts -arrows- and detach bearing saddle, = Tum vibration damper to "TDC" position -arrow- using coun- terhold - 710355- + Notch on vibration damper must align with arrow marking on ‘cover for timing chains (bottom), + The markings -1- on the camshafts must face upwards. 8.vaeocer 185@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 = Mark positions of sprocnet markings -1- on camshaft timing chain and eylindr head -arows- using @ pemanent fl tip marker. = Also mark alignment of camshaft timing chain -2- relative to uide rail of camshaft timing chain using @ permanent felt tip marker. — Remove sealing plug -arrow- — Unscrew bolts -arrows-.. = Unscrew bolt -arrow-. 186 ep. or18-cyindr noad, vate gsarCC 2010 > , Eos 2006 > , Golf 2004 : > , Golf 2009 > , Passat 2006 > .... (@) ALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 Depending on version, either of two different chain tensioners may be installed. Version 1: = Screwin lever - T40243- -arrows-. w hte Ifit is not possible to insert the lever - T40243-, the distance between the timing chain and the ol deflector on the fower cover is too siral) Itis then necessary to remove the lower cover. @ Passat, CC = page 92 * Golf, Eos, Scirocco = page 98 Tiguan 2 page 105 = Raise locking element of chain tensioner -arrow 1-. To do this ging the tip ofthe locking pin - T4001. to apoint A screw, river with a blade width of approx. 1.5 mm can also be used. A 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 = Secure chain tensioner with locking pin =.7400' = “Screw in lever - 140243- -arrows- [i] we» Ifitis not possible to insert the lever - T40243-, the distance batween the timing chain and the oil deflector on the lower cover is too small. It is then necessary to remove the lower cover © Passat CO > page 92 = Press together secure -errow- of cha tens. Then slowly push lever - 40243. ini-direction of arrow- and hold it in thet postition T4023 ~My 8.vaeocer 187@ CC 2010 > , Eos 2006 > , Golf 2004 > , Golf 2009 > , Passat 2006 ~ ... 4-cy injection engine 1.8 and 2.0 | engine, chain dr ~ Secure chain tensioner with locking pin - T40267- All — Remove le.er-T4u243- — Bolt camshaft clamp - T4027 1/2- to cylinder head and insert it indirection of arrow-2- between teeth of sprocket. necessary tum inlet camshaft slightly direction of arrow_-1- using span- ner. = Bolt camshaft clamp - 740271/1- to cylinder head. Counter- hold camshaft cloc: wise -arrow- using open-end spanner Remove bolt -A- and take out tensioning rail downwards. In the process. continue to countemhold the camshaft, Edition 02.2017 188 ep. 0-19 cyind noad, vate gsarALcyl. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 - Tum exhaust camshaft clockwise -1- until camshaft clamp - 74027 1/1- can Le inseried into sprockei splines — Use screwdriver to release fastener and press off top guide rail towards front -1-, Mark position of sprockets -Lrrow- rele. tive to camshaft clamp. — Remove camshaft timing chain from camshatt sprockets, LX cauton Risk of damaging valves, piston crowns and lower timing chain cover. '¢ Ensure the timing chain is always under tension when turing the crankshaf. ¢ Plates to prevent the chain faling down are attached to the lower timing chain cover. If the crankshaft 3 turned ~ when the chain is loose, the plates may bend.” If the camshafis are renewed, the markings which you applied ‘earlier must be transferred. To do so, proceed as follows: Before removing camshafts, mark alignment of camshaft sprockets relative to camshaft clamp - 140271/1- and cam- shaft clamp - 140271/2- -arrow-, (#) Note é The following measurement of distances is later used to check Whether the markings have been correctly transferred. 8.vawe acer 189@ CC 2010 > , Eos 2006 > . Golf 2004 > , Golf 2009 > , Passat 2006 >... 4-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 - Measure distance from left outer edge of web -A- to marking -B- on inlet camshaft and record figure. — Measure distance from marking on inleti¢amshaft -B- to mark- ing on exhaust camshaft -C- and record figure. = Tum inlet camshaft in -direction of arrow 1- using spanner, remove camshaft clamp - 140271/2- in -direction of arrow 2- from between teeth of sprocket and bring camshaft into rest position. 190 ep. 18 cyindr noad, vate gsarCC 2010 > , Eos 2006 » , Golf 2004 > «Golf 2009 > , Passat 2006 > , 4-cy/, injection engine (1'8 and 2.0 | engine, chain drive) - Ealtion 02.2017 - Tum exhaust camshaft in direction of arrow 1- using spanner, remove camshaft clamp - 140271/1- in -direction of arrow from between teeth of sprocket and bring camshaft interest position. = Removing ignition coils with output stages = page 553 Engine codes CCZA, CCZB, CDAA, CDAB: — Separate crankcase breather hoses -1 and 2. = Remove bolts -arrows- and remove crankcase ureather. Engine codes CBFA, CCTA: ~ Disconnect crankcase’breather hose -1~. — Unscrew bolts -arrows-. ~ Unscrew bolt -arrow for ir pipe Loosen hose clip -1- and remove air pipe together with crank- case breather. 8.vave acer 1914-cy/. injection engine (1.8 and 2.0 | engine, chain drive) - Edition 02.2017 All: — Disconnect vacuum line -1- and move line to one side. = Pull off connector -2- from Hall sender - G40- ~ Undo nl remove eyinder head cover bots inthe sequence ne = Remove cylinder head cover. = Detach camshafts. - Prevent dirt and residual sealant from entering cylinder head, Installing camshafts fnew camshafts are to be fitted, transfer the markings which you made on the removed camshafts to the new ones. + Specified torques = page 180 (8 vow ws % After installing camshafts wait for aporox. 30 minutes before starting engine: The hydraulic compensation elements must settle (otherwise vaives will strike pistons). After working on the valve gear, tum the engine carefully at least 2 rotations to ensure that none of the valves make con- tact when the starter is operated. % Sealing surfaces must be free of oil and grease. 4 The pistons cannot be postioned at TDC. # Ensure that all roller rocker fingers ars properly seated on z vatve stem ends. 2 % Noteiexpity date of silicone sealant. The cover must be installed within S minutes after applying the silicone sealant. + Prevent dirt and residual sealant from entering ¢;Jinder head. — Remove Sealant remaining on cylinder head with fiat scraper. Ly warns Wear satety goggles. g 192 pep. o-18-cyindr noad, vate gsar