Removing and installing cylinder head (engine codes CBDA, CBDB, CEGA) — VW

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018), VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Opens: coolant, brake fluid
• Timing position: the crankshaft or camshaft is set and locked during this job
• Renewed: cylinder head bolts

Don't miss

• The lower bolt on the exhaust gas recirculation cooler can be unscrewed with the special wrench, long reach T10385.
• The exhaust gas temperature sender 1G235 covers the upper threaded connection of the turbocharger support and must not be bent. It must therefore be removed. — Remove exhaust gas temperature sender 1G235(1).
• Cylinder head gasket must lie with identification facing upwards.
• The tensioning roller must be pushed onto studs when fitting the cylinder head.
• Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop T10050.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all the various lines and electrical wiring so that they are in their original positions.e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid, vacuum.Ensure that there is sufficient clearance to all moving or hot components. — Disconnect earth strap at battery with ignition switched off Electrical system27Disconnecting and reconnecting battery.
2. Remove engine cover panel .
3. Remove air filter housing .
4. Remove battery and battery holder Electrical system27Removing and installing battery.
5. Remove cowling together with radiator fan V7 and radiator fan on right of radiator V35.

6. Remove connecting hose on »cold side« from charge air cooler.
7. Remove cylinder head cover .
8. Take toothed belt off camshaft .
9. Pull connectors off exhaust gas recirculation valve N18(1) and off throttle valve module J338(3).
10. Unscrew bolts from oil dipstick attachment (arrow) and from connecting pipe for exhaust gas recirculation (2).
11. Remove cowling together with radiator fans .
12. Remove securing bolts (arrows) from charge air pipe and separate connector (1) from charge air pressure sender G31.
13. Open clamp (2), lay coolant hose (3) to side and remove charge air pipe.
14. Disconnect vacuum line from vacuum pump.
15. Unclip engine pre-wiring harness from retainer (arrow).
16. Pull off vacuum line (arrow).
17. Unscrew vacuum line attachment (arrow).
18. Unscrew securing bolts of charge air pipe and pull connecting hose off turbocharger.
19. Remove vacuum pump from cylinder head .
20. Disconnect connector (arrow) from coolant temperature sender G62 and guide line out.
21. ⚠ Ensure decoupling element of connecting pipe is not bent and thus stretched. There is a danger of cracking. — Remove exhaust gas recirculation connecting pipe . [Note: The lower bolt on the exhaust gas recirculation cooler can be unscrewed with the special wrench, long reach T10385.]
22. Remove noise insulation General body repairs, exterior50Body - front; Assembly overview - noise insulation..
23. Drain coolant .
24. Loosen securing nuts (arrows) of bracket for diesel particulate filter (A) at crankcase.
25. Release connecting clamp between turbocharger and diesel particulate filter.
26. Unscrew securing bolt from bracket on cylinder head (arrow) and push diesel particulate filter to side.
27. Remove connecting pipe (A) to exhaust gas recirculation cooler.
28. ⚠ The exhaust gas temperature sender 1G235 covers the upper threaded connection of the turbocharger support and must not be bent. It must therefore be removed. — Remove exhaust gas temperature sender 1G235(1).
29. Unscrew bolt (arrow) from support on turbocharger.
30. Pull coolant hoses off coolant connection of cylinder head.
31. Unscrew bolt of oil supply line (arrow) and remove oil supply line.
32. Remove camshaft toothed belt pulley and pull off camshaft hub using puller T10052.
33. Unscrew securing bolt (arrow) of toothed belt guard.
34. Unscrew securing nut of toothed belt tensioning roller.
35. Separate connector for Hall sender G40(arrow).
36. Maintain sequence when loosening cylinder head bolts. [Note: A second mechanic is required for the removal of the cylinder head.The toothed belt tensioning roller is pulled off the stud when the cylinder head is lifted out.The oil return line of the turbocharger is pulled out of the support when the cylinder head is lifted out.]
37. First lift cylinder head on gearbox side and guide it out of toothed belt guard. Prevent toothed belt tensioning roller from falling down.
38. Place cylinder head down taking care not to bend oil return line. If necessary, place a piece of wood under exhaust manifold. [Note: Always renew cylinder head bolts.In cases of repair carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. When using abrasive paper do not use a grade less than 100.Carefully remove emery and abrasive remains.Do not remove new cylinder head gasket from packaging until it is ready to be fitted.Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks.]
39. ⚠ 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 coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.Ensure that cylinder head gasket seals properly:Carefully remove remains of emery and abrasives.Do not remove new cylinder head gasket from packaging until it is ready to be fitted.Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket.Avoid damage to open valves:When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted.Avoid damage to valves and piston crowns after working on valve gear:Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.Before installing, check whether decoupling element of oil return line is bent and thus stretched. If this is the case, micro cracks may have formed and may cause leakage. If necessary, renew oil return line of cylinder head before installing. — Before fitting cylinder head, remove crankshaft stop T10050 and turn crankshaft opposite direction of rotation until all pistons are nearly uniformly below TDC.
40. Cylinder head gasket must lie with identification facing upwards.
41. To centre, screw guide pins3070 into outer threaded holes on intake side. [Note: The tensioning roller must be pushed onto studs when fitting the cylinder head.]
42. Fit cylinder head, install 8 cylinder head bolts and hand-tighten.
43. Remove guide pins through bolt holes using removal tool from 3070 and install cylinder head bolts.
44. Tighten cylinder head in 4 stages in sequence shown as follows:
45. Secure rear toothed belt guard to cylinder head.
46. Install hub and camshaft pulley.
47. Lock camshaft and high-pressure pump with diesel injection pump locking pin3359
48. Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop T10050.
49. Fit toothed belt .
50. Install cylinder head cover .
51. Install poly V-belt .
52. Replenish coolant .
53. Carry out road test and read all fault memories.

Other VW procedures

• Removing and installing engine mountings · 7 torque figures
• Removing and installing sealing flange on pulley end – VW · 6 torque figures
• Removing and installing 4/2-way valve with thermostat · 5 torque figures
• Renewing vacuum unit for turbocharger · 3 torque figures
• Installing a new balancer shaft module – VW · 5 torque figures
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures