Removing and installing cylinder head (engine codes CBEA, CJAA) — VW

🧭 Before you start

Strip the top of the engine, remove the toothed belt from the camshaft and disconnect sensors, charge air pipes and vacuum lines. From below, release the particulate filter, EGR filter and turbocharger support, drain the coolant and undo the head bolts in sequence with a helper to lift the head out past the rear belt guard. Clean both faces, fit the new gasket with the marking up, centre the head on guide pins and tighten in 4 stages. Lock the camshaft and crankshaft at TDC to refit and tension the belt, then refit the exhaust parts stress-free in the stated order, refill coolant and fill the fuel system.

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, seals, nuts

Don't miss

• Always renew the cylinder head bolts, seals, gaskets, self-locking nuts and securing clamps.
• Gasket goes on with the identification facing upwards; leave it in its packaging until the moment it is fitted.
• Remove oil and coolant from the bolt blind holes in the block before the head goes down.
• Do not bend the filter decoupling element more than 10° and install it free of tension.
• Set pistons slightly below TDC before fitting the head, then turn the engine at least 2 rotations by hand afterwards.
• Lift the head with a second person; the tensioning roller and turbo oil return line come out with it.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 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. — Remove engine cover panel .
2. Remove air filter housing .
3. ⚠ To prevent damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect earth wire (arrow) from battery with ignition switched off Electrical system27Disconnecting and reconnecting battery.
4. Remove battery and battery tray (arrows).
5. Remove cylinder head cover .

6. Take toothed belt off camshaft , Removing and installing toothed belt.
7. Remove camshaft toothed belt pulley and hub , Removing and installing camshafts.
8. Pull connectors off exhaust gas recirculation valve N18(1) and off throttle valve module J338(3).
9. Loosen clamp (4) and pull off charge air hose.
10. Unscrew bracket (arrows) for oil dipstick.
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. Remove oil supply line .
15. Unclip wiring harness to engine control unit out of cable guide (arrows).
16. Remove vacuum pump .
17. Pull connector off position sender for charge pressure positioner G581(2) at turbocharger vacuum unit.
18. Pull vacuum hose (3) off turbocharger vacuum unit.
19. Disconnect »black« connector for exhaust temperature sender 1G235(2) at plenum chamber bulkhead.
20. Guide lines out of retainers on plenum chamber bulkhead and on turbocharger.
21. Remove noise insulation General body repairs, exterior50Body - front; Noise insulation.
22. Remove heat shield for right drive shaft (arrows).
23. Unscrew securing bolts of charge air pipe and pull connecting hose off pulsation damper on turbocharger.
24. Mark installation position of exhaust temperature sender 1G235 and remove.
25. Unbutton heat shield and pull connector off exhaust gas pressure sensor 1G450.
26. Remove control line between exhaust gas recirculation housing and exhaust gas pressure sensor 1G450.
27. Unscrew securing bolt and remove bracket with exhaust gas pressure sensor 1G450 and move aside (control line to particulate filter remains connected).
28. Remove lower bracket for particulate filter. [Note: Unscrew securing nuts above bracket with ratchet ring spanner T10384.]
29. Remove exhaust gas recirculation filter .
30. Pull connector (arrow) off coolant temperature sender G62 and guide line out.
31. Remove particulate filter from upper bracket and loosen bracket on cylinder head.
32. Remove securing clamp between particulate filter and turbocharger.
33. Remove banjo bolt of turbocharger support.
34. Unscrew hexagon drive stud from support on turbocharger.
35. Turn lower part of support 90° and pull support downwards off upper part.
36. Pull coolant hoses off coolant connection of cylinder head.
37. Unscrew securing bolt (arrow) for toothed belt rear guard.
38. Unscrew securing nut of toothed belt tensioning roller .
39. Separate connector for Hall sender G40(arrow).
40. Drain coolant .
41. Remove cylinder head bolts in sequence: (1…10). [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.Check that all relevant electrical wiring has been disconnected.]
42. First lift cylinder head on gearbox side and guide it out of toothed belt rear guard. Prevent toothed belt tensioning roller from falling down.
43. 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.Renew seals, gaskets and self-locking nuts and securing clampsIn 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.]
44. ⚠ 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.
45. Cylinder head gasket must lie with identification facing upwards.
46. 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.]
47. Fit cylinder head, install 8 cylinder head bolts and hand-tighten.
48. Remove guide pins from bolt holes with removal tool from 3070 and install cylinder head bolts.
49. Tighten cylinder head in 4 stages in sequence shown as follows:
50. Secure toothed belt rear guard to cylinder head.
51. Install hub for camshaft pulley , Removing and installing camshaft.
52. Lock camshaft and high-pressure fuel pump with locking pin3359.
53. Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop T10050.
54. How to install and tension toothed belt . [Note: After working on the particulate filter with NOx storage catalytic converter, ensure it is installed free of stress.Always renew nuts, seals, gaskets and securing clamps.]
55. ⚠ Danger of damaging decoupling element between particulate filter and NOx storage catalytic converter. When removing and installing:Do not bend decoupling element more than 10°.Install decoupling element so that it is not under tension.Take care not to damage wire mesh on decoupling element. — Position lower bracket on cylinder block and on particulate filter with securing nuts. (Do not tighten securing nuts yet).
56. Position new securing clamp with new seal between particulate filter and turbocharger (do not tighten securing clamp yet):
57. Install exhaust gas recirculation filter .
58. Position new securing clamp between particulate filter and filter for exhaust gas recirculation (do not tighten securing clamp yet):
59. Position particulate filter on upper bracket with securing bolt. (Do not tighten securing bolt yet).
60. Tighten fasteners in the following sequence:

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