2.0L - Cylinder Head, Valvetrain - Engine Code(s): Cbfa & Ccta: Overview Volkswagen Eos I

CYLINDER HEAD OVERVIEW

Note. Replace the cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to a torque angle, as well as gaskets and O-rings. The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head. When replacing the cylinder head or cylinder head gasket, the coolant must be completely replaced.

Scheme 200

1. Cylinder Head Gasket Always replace. Note the installed position: Part number faces the cylinder head.
2. Bolt 25 Nm
3. Transport Strap
4. Bolt Tightening sequence (Scheme 203)
5. Cylinder Head Removing and installing, refer to «CYLINDER HEAD»(ref-475580-S36795753362012052300000). Checking for distortion (Scheme 204)
6. Bolt Always replace. Observe the sequence for loosening (Scheme 202) Observe the sequence for tightening (Scheme 203)
7. O-ring Always replace. Lubricate with engine oil.
8. Ball Stud 5 Nm With a ball head for the engine cover.
9. Cap With a seal.
10. O-ring Always replace. Lubricate with engine oil.
11. Sealing Plug
12. Bracket
13. Bolt 9 Nm
14. Heat Shield
15. Bolt 20 Nm
16. Bolt 20 Nm
17. to the Intake Hose/Turbocharger
18. Ventilation Pipe
19. O-ring No replacement part.
20. Gasket No replacement part.
21. Engine Cover
22. Bolt Tightening sequence (Scheme 201)
23. Crankcase Ventilation Observe the tightening sequence (Scheme 201)
24. to the Intake Manifold
25. Gasket No replacement part.
26. Gasket Replace if damaged.
27. Vacuum Pump Removing and installing, refer to «VACUUM PUMP»(ref-475580-S12837404262012052300000).
28. Bolt 9 Nm
29. Bolt 9 Nm For engine code CBFA only.
30. Secondary Air Injection Solenoid Valve -N112- For engine code CBFA only.
31. Gasket Always replace. For engine code CBFA only.
32. Mounting Plate
33. Bolt 9 Nm
34. Connecting Piece
35. O-ring Always replace. Lubricate with coolant.
36. Bolt 25 Nm
37. Transport Strap
38. Bolt 9 Nm
39. Camshaft Position Sensor -G40
40. Partition Plate

Scheme 201

Tighten the crankcase ventilation bolts -1 to 10- in sequence to 11 Nm.

Scheme 202

Remove the bolts -arrows-.

Loosen the cylinder head bolts in sequence -1 through 5-.

Scheme 203

Tighten the cylinder head bolts in sequence -1 through 5-.

Tighten the bolts to 40 Nm using a torque wrench.

Tighten the bolts an additional 90° (1/4) turn using a ratchet.

Tighten the bolts an additional 90° (1/4) turn using a ratchet.

Tighten the bolts -arrows- to 8 Nm.

Tighten the bolts -arrows- an additional 90° (1/4) turn using a ratchet.

Scheme 204

Check the cylinder head at several locations for distortion using a straight edge 500 mm -VAS 6075- and a feeler gauge.

1. Max. permissible distortion: 0.05 mm

VALVETRAIN OVERVIEW

Note. The cylinder head and the cylinder head cover must be replaced together. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic lash adjusters must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons. Always replace gaskets and seals.

Scheme 205

1. Exhaust Valve Do not grind, only hand lapping is permitted. Valve dimensions (Scheme 207) Checking valve guides, refer to «VALVE GUIDE, CHECKING»(ref-475580-S35367842212012052300000).
2. Cylinder Head
3. Valve Guide Checking, refer to «VALVE GUIDE, CHECKING»(ref-475580-S35367842212012052300000).
4. Valve Stem Seal
5. Valve Spring
6. Valve Spring Plate
7. Valve Retainers
8. Roller Rocker Arm with Hydraulic Lash Adjuster Do not interchange. Lubricate the contact surfaces.
9. Exhaust Camshaft Check the radial clearance using Plastigage R (roller rocker arm removed). Radial play on bearing diameter - 24 mm: 0.024 to 0.066 mm. Radial play on bearing diameter - 32 mm: 0.030 to 0.051 mm. Run out: Max. 0.04 mm.
10. Cylinder Head Cover With integrated camshaft bearings. Clean the sealing surface, reworking is not permitted. Remove the old sealant residue.
11. Bolt Always replace. Tightening sequence (Scheme 206)
12. O-ring Always replace. Lubricate with engine oil.
13. Sealing Plug
14. Intake Camshaft Check the radial clearance using Plastigage R (roller rocker arm removed). Radial play on bearing diameter - 24 mm: 0.024 to 0.066 mm. Run out: Max. 0.04 mm.
15. Cap Always replace. Removing: With the cylinder head cover installed, pierce through one side of the cover with an awl and pry it out. Installing: Without sealant, press in 1 to 2 mm using the thrust piece -3334-.
16. Intake Valve Do not grind, only hand lapping is permitted. Valve dimensions (Scheme 207) Checking the valve guides, refer to «VALVE GUIDE, CHECKING»(ref-475580-S35367842212012052300000).

Scheme 206

Replace the bolts.

Hand tighten the bolts in several passes in sequence -1 through 6-.

Tighten the bolts in sequence -1 through 6- to 8 Nm using a torque wrench.

Tighten the bolts an additional 90° (1/4) turn using a ratchet in sequence -1 through 6-.

Note. Ensure the cylinder head cover is not tilted.

Scheme 207

Note. Intake and exhaust valves must not be refaced by grinding. Only hand lapping is permitted.

Scheme 208

1. O-ring Always replace. Lubricate before installing.
2. Oil Dipstick Guide Tube
3. Bolt 9 Nm
4. Bolt 9 Nm
5. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «CAMSHAFT ADJUSTMENT VALVE 1 -N205»(ref-475580-S17347140792012052300000).
6. Seal Lubricate before installing. Replace if damaged.
7. Bolt Tightening sequence, refer to «UPPER TIMING CHAIN COVER»(ref-475580-S22975654232012052300000).
8. Upper Timing Chain Cover Removing and installing, refer to «UPPER TIMING CHAIN COVER»(ref-475580-S22975654232012052300000). Tightening sequence (Scheme 209)
9. Gasket Replace if damaged.
10. O-ring Always replace. Lubricate before installing.
11. Alignment Sleeve For centering the cover.
12. Lower Timing Chain Cover Tightening sequence (Scheme 210) Removing and installing, refer to one of the following: GTI and Eos, refer to «LOWER TIMING CHAIN COVER»(ref-475580-S34392614592012052300000).
13. Bolt Always replace. Observe the tightening sequence (Scheme 210).
14. Shaft Seal For the vibration damper. Removing and installing, refer to «VIBRATION DAMPER SHAFT SEAL»(ref-475580-S00158383342012052300000).
15. Sealing Plug Always replace.

Scheme 209

Tighten the bolts in 2 passes in sequence -1 through 5

1. Tighten the bolts by hand
2. Tighten the bolts to 9 Nm

Scheme 210

Tighten the bolts in 2 passes in sequence -1 through 15

1. Tighten the bolts to 8 Nm
2. Tighten the bolts an additional 45° (1/8) turn

Scheme 211

1. Bolt 9 Nm
2. Chain Tensioner Is under tension. Disconnect the locking pin -T40011- before removing.
3. Timing Chain Tensioning Rail
4. Guide Pin 20 Nm
5. Bolt 9 Nm
6. Control Valve 35 Nm Left hand threads. Remove using the assembly toolT10352.
7. Bolt M6 bolt: 8 Nm + an additional 90° (1/4) turn. M8 bolt: 20 Nm + an additional 90° (1/4) turn. Always replace.
8. Washer
9. Bearing Bracket
10. Camshaft Timing Chain Guide Rail
11. Camshaft Housing
12. Camshaft Timing Chain Before removing, mark the direction of rotation with paint. Removing and installing, refer to «CAMSHAFT TIMING CHAIN»(ref-475580-S22635267992012052300000).
13. Camshaft Timing Chain Guide Rail
14. Guide Pin 20 Nm
15. Sprocket On the crankshaft. Installed position (Scheme 212)

Scheme 212

1. Both surfaces -arrows- must line up across from each other.

Scheme 213

1. Bolt 9 Nm
2. Balance Shaft Replace after removing. Exhaust side. Lubricate the bearing with engine oil. Removing, refer to «EXHAUST CAMSHAFT BALANCE SHAFT»(ref-475580-S29938159882012052300000).
3. Pipe for the Balance Shaft Installed position (Scheme 214)
4. Chain Tensioner 65 Nm Install using liquid locking fluid.
5. Cylinder Block
6. Balance Shaft Replace after removing. Intake side. Lubricate the bearing with engine oil. Removing, refer to «INTAKE CAMSHAFT BALANCE SHAFT»(ref-475580-S20701135562012052300000).
7. O-ring Lubricate with engine oil.
8. Bearing Pin Lubricate with engine oil. Installed position (Scheme 215)
9. Intermediate Shaft Sprocket For the balance shaft. The intermediate shaft sprocket must be replaced if the bolt is loosened.
10. Bolt 9 Nm
11. Washer
12. Bolt The intermediate shaft sprocket must be replaced if the bolt is loosened. Tightening sequence (Scheme 216)
13. Guide Rail For the timing chain.
14. Guide Pin 20 Nm
15. Tensioning Rail For the timing chain.
16. Guide Pin 20 Nm
17. Timing Chain Removing and installing, refer to «BALANCE SHAFT TIMING CHAIN»(ref-475580-S29956811732012052300000).
18. Sprocket Installed position (Scheme 212)
19. Guide Rail For the balance shaft timing chain.
20. Guide Pin 20 Nm

Scheme 214

1. The pin from the balance shaft pipe must fit into the groove -arrow

Scheme 215

1. Replace and lubricate the O-ring -1
2. The pin -arrow- for the bearing pin must engage in the hole in the cylinder block.
3. Lubricate the bearing pin.

Scheme 216

Tighten the bolt as follows

Tighten the bolt to 10 Nm using a torque wrench.

Turn the chain sprocket.

The chain sprocket may not have any play; if so, loosen and tighten again.

Tighten the bolt to 30 Nm using a torque wrench.

Tighten the bolt an additional 90° (1/4) turn using a ratchet.