Fitting the cylinder head cover: VW 1.2 (CBZA, CBZB)

🧭 Before you start

Fits: platform code AJ5

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T10288/4

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• Clean sealing surfaces carefully. They must be free of oil and grease.
• The studs guide the cylinder head cover during fitting. This prevents the roller rocker fingers from slipping out of the compensation elements.
• Cylinder head cover is sealed using 2 different sealants! — Clean sealing surfaces carefully. They must be free of oil and grease.
• Turn crankshaft in normal direction of rotation until the stop.
• Securing bolt is not tightened by a 1/4 turn (90°) further until after timings have been checked at end of procedure.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ Studs (M6x70) must be screwed into cylinder head before cylinder head cover is installed.The cylinder head cover is guided by the studs, so that the roller rocker fingers do not slip off the supporting elements. — Remove sealant residues from cylinder head and cylinder head cover with a rotating brush, e.g. a hand drill with a plastic brush (wear eye protection).
2. Clean sealing surfaces carefully. They must be free of oil and grease.
3. Also prevent dirt and residual sealant from entering cylinder head.
4. Screw two studs (M6x70) (1) (for example T10288/4) into cylinder head before fitting cylinder head cover. [Note: The studs guide the cylinder head cover during fitting. This prevents the roller rocker fingers from slipping out of the compensation elements.] [Note: Sealant must not be applied too thickly; otherwise excess sealant can enter oil channels and cause damage to engine.]
5. ⚠ Cylinder head cover is sealed using 2 different sealants! — Clean sealing surfaces carefully. They must be free of oil and grease.

6. Apply sealantD 189 500 A1 to the sealing surface (1).
7. Apply sealantD 154 103 A1 thinly and evenly on the surfaces marked with diagonal lines (2).
8. Check that roller rocker fingers are in contact with support elements.
9. Carefully place cylinder head cover over studs and dowel pins onto cylinder head.
10. Tighten new securing bolts in cylinder head cover in specified sequence (1) to (12).
11. ⚠ It is essential to remove sealant for cylinder head cover in area of (arrows).In order to avoid leaks, do not mix together both sealants for cylinder head cover and for valve timing housing. — Remove surplus sealant in area of (arrows).
12. Turn crankshaft in normal direction of rotation until the stop.
13. Raise timing chain using assembly tool T10118.
14. ⚠ Sump only needs to be removed on vehicles ► 12.2009.On these vehicles, timing chain can slip off crankshaft chain sprocket during installation! — From underneath, check timing chain (1) is in correct position on crankshaft chain sprocket.
15. Place timing chain (1) onto chain sprocket (2).
16. Tighten new securing bolt for camshaft sprocket only hand-tight.
17. Tighten chain tensioner (arrow) to 60 Nm. — 60 Nm (44 lb-ft)
18. Tighten bolt (1) to 50 Nm. [Note: Securing bolt is not tightened by a 1/4 turn (90°) further until after timings have been checked at end of procedure.] — 50 Nm (37 lb-ft)
19. When doing this, hold camshaft toothed belt pulley with counter-hold tool T10172.
20. Remove locking pin T10414 from camshaft.
21. Unscrew locking pin T10340 from cylinder block.
22. Turn crankshaft 2 revolutions in normal direction of rotation.
23. Screw locking pin T10340 to stop into crankcase.
24. Turn crankshaft in normal direction of rotation until the stop.
25. Repeat valve timing adjustment.
26. Turn securing bolt a (1)1/4 turn (90°) further.
27. When doing this, hold camshaft toothed belt pulley with counter-hold tool T10172.
28. Remove locking pin T10414 and locking pin T10340.
29. Restore current supply to fuel pump.

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