2.5l - Cylinder Head, Valvetrain - Engine Code(s): Bpr & Bps (hatchback) Volkswagen New Beetle A4 рестайлинг

GENERAL REPAIR INFORMATION

Note. If a replacement cylinder head is installed, several contact surfaces between the support elements, roller cam followers and cam lubricating surfaces of the camshaft must be oiled before installing the cylinder head cover. The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head. Replace the cylinder head bolts. When replacing the cylinder head or cylinder head gasket, the coolant must be completely replaced.

Note. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a Max. width 0.3 millimeters (mm), or only the first 4 threads of the spark plug threads are cracked. The cylinder head and guide frame may only be replaced together. Do not grind the valve seats in the cylinder head, only lapping the valves is permitted. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons). After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting the engine to be sure that valves do not strike the pistons. Always replace gaskets and seals.

VALVE TIMING, ADJUSTING

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Torque wrench (40-200 Nm) VAG 1332
3. Locking pin T03006
4. Multipoint socket T10035
5. Counterhold tool T10172
6. Camshaft clamp T40070
7. 2 bolts M8 x 16

Modifying T10172

Scheme 1

Remove the T10172/1 and install 2 M8 x 16 bolts -A-.

Note. The valve timing must be adjusted if the camshaft sprockets were loosened during repairs or if the valve timing is not set.

Securing the Camshafts if the Valve Timing is Correct

Remove the chain compartment cover. Refer to CHAIN COMPARTMENT COVER .

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Lock the crankshaft for adjusting the valve timing. Refer to CRANKSHAFT, LOCKING TO CHECK/ADJUST VALVE TIMING .

Install the T40070 as shown onto the camshafts and tighten the bolts to 20 Nm.

Scheme 2

If the bolts could not be installed easily, attempt to rotate the exhaust camshaft at the recess using an open end wrench -A- (18 or 19 millimeter (mm), depending on the wrench width) slightly in the -direction of the arrow- in order to eliminate any play in the chain drive.

Relieve the tension on the timing chain. To do so, insert a screwdriver of the appropriate size between the timing chain tensioner piston and the tensioning rail and press the piston in -direction of the arrow-.

Scheme 3

Secure the completely pressed in piston using T03006. The T03006 must be installed until it stops.

Securing the Camshafts if the Valve Timing is Not Correct

Remove the chain compartment cover. Refer to CHAIN COMPARTMENT COVER .

Rotate the crankshaft to Top Dead Center (TDC) for cylinder 5, refer to CRANKSHAFT, LOCKING TO CHECK/ADJUST VALVE TIMING , however do not peg the crankshaft using T40069.

Rotate the crankshaft so that T40070 can be installed easily onto the camshafts as shown.

Tighten the bolts for the T40070 to 20 Nm.

Removing the Camshaft Sprocket/Actuator

Relieve the tension on the timing chain. To do so, insert a screwdriver of the appropriate size between the timing chain tensioner piston and tensioning rail and press in -direction of the arrow-.

Secure the completely pressed in piston using T03006. The T03006 must be inserted until it stops.

Remove the bolts -1 and 4- using T10035 and remove the actuator -2- and sprocket -3-.

If necessary, the sprocket -3- must be pried off slightly using a screwdriver.

Note. Lock the crankshaft, refer to CRANKSHAFT, LOCKING , if not yet secured. Crankshaft must only be rotated slightly around the TDC point for this. Otherwise there is a risk the valves rest on the pistons.

Valve Timing, Adjusting

1. Crankshaft secured by the T40069
2. Camshafts secured by the T40070
3. Chain tensioner is tensioned

Place the actuator -2- and sprocket -3- into the timing chain, place them onto the camshafts and hand tighten the new bolts -1 and 4-.

Sprockets must still be able to be rotated, however they must not tilt.

Note. Make sure that the timing chain lies correctly in the guide and tensioning rails.

Relieve the tension on the chain tensioner by pressing in the piston and pulling out the T03006.

Install the modified T10172 to the exhaust camshaft sprocket -4-.

Scheme 4

Note. A second mechanic is required for the following steps.

Hold the timing chain at preload by pressing the T10172 in the -direction of the arrow-.

Simultaneously tighten the camshaft actuator bolt -2- first and then the exhaust camshaft sprocket bolt -3- to 60 Nm.

Then tighten the bolts -2 and 3- and additional 90° (1/4) further.

Note. When applying the additional torque of 90°, the timing chain must no longer be held at preload.

Remove the T40070.

Remove the T40069.

Scheme 5

Turn the crankshaft 2 revolutions in the engine running direction and lock the crankshaft CRANKSHAFT, LOCKING TO CHECK/ADJUST VALVE TIMING .

Check the valve timing. Refer to VALVE TIMING, CHECKING .

If the valve timing is not correct

Loosen the sprocket/actuator bolts again and adjust the valve timing again (replace the camshaft bolts).

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt.
2. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

Scheme 6

1. Bolt, 10 Nm
2. Cylinder Head Cover With pressure regulator valve for the crankshaft housing ventilation. Bleeder hose to intake manifold, see «INTAKE MANIFOLD AND ATTACHMENTS ASSEMBLY OVERVIEW => Hose for Crankcase Ventilation»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback). Tightening sequence (Scheme 7) Removal and installation, refer to «CYLINDER HEAD COVER»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__cylinder-head-cover).
3. Cylinder Head Cover Gasket Replace if damaged or leaking.
4. Bolt, 10 Nm
5. Oil Filler Cap
6. Gasket Replace if damaged or leaking
7. Bolt, 10 Nm
8. Bleeder Hose for Crankcase Ventilation Ensure the hose is securely seated. To disengage, squeeze together the securing ring.
9. to Intake Hose/Intake Manifold
10. Wire Bracket
11. Seal Replacing, refer to «CHAIN COMPARTMENT COVER SEAL»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__chain-compartment-cover-seal).
12. Wire Bracket
13. Chain Compartment Cover Removal and installation, refer to «CHAIN COMPARTMENT COVER»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__chain-compartment-cover).
14. Bolt, 2 Nm
15. Camshaft Adjustment Valve 1 -N205- Checking, refer to vehicle diagnostic tester VAS 5051B "Guided Fault Finding".
16. O-ring Replace if damaged
17. Bolt 10 Nm
18. Camshaft Position (CMP) Sensor -G40
19. Transport Strap
20. Bolt, 25 Nm
21. Cylinder Head Gasket Replace After replacing, replace the entire amount of coolant.
22. Cylinder Head Removal and installation, refer to «CYLINDER HEAD»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback). Checking cylinder head for warpage (Scheme 8) It is not permitted to rework the sealing surface With the coolant pipe connection pressed in. -- If necessary, remove coolant deposits using a copper wire brush or fine sandpaper (minimum 100 grit). -- If the pipe connection is worn, replace it using locking fluid D 000600 A2.
23. Bolt, 40 Nm + 180° (1/2) additional turn Replace Follow the sequence for loosening and tightening. Refer to «CYLINDER HEAD»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback).
24. Wire Bracket For the Heated Oxygen Sensor (HO2) -G39-.

Scheme 7

Scheme 8

Check the cylinder head at multiple points for distortion with a straight edge 500 mmVAS 6075 and feeler gauges.

1. Max. permissible distortion: 0.05 millimeters (mm)

If this value is exceeded, the cylinder head must be replaced. It is not permissible to rework the sealing surface.

Scheme 9

1. Bolt, 8 Nm + 90° (1/4) additional turn Replace
2. Guide Frame Removal and installation, refer to «CAMSHAFTS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__camshafts) . With integrated camshaft bearings. Clean the sealing surface, reworking is not permitted. Remove old sealant residue.
3. Exhaust Camshaft Sprocket
4. Bolt, 60 Nm + 90° (1/4) additional turn Replace
5. Bolt, 60 Nm + 90° (1/4) additional turn Replace
6. Intake Camshaft Adjuster
7. Seals For the camshaft adjuster. Note the installed position, refer to «CAMSHAFTS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__camshafts) .
8. Timing Chain Removing from the sprocket/actuator, refer to «VALVE TIMING, ADJUSTING»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-timing-adjusting) .
9. Cylinder Head Do not grind the valve seats, only lapping is permitted.
10. Hydraulic Valve Play Balancing Element Do not interchange Lubricate the contact surface.
11. Valve Keepers
12. Top Valve Spring Retainer
13. Valve Spring
14. Valve Stem Seal Replacing, refer to «VALVE STEM SEALS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-stem-seals) .
15. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-guides-checking) .
16. Intake Valve Do not grind, only lapping is permitted. Valve dimensions, refer to «VALVE DIMENSIONS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-dimensions) . Checking valve guides, refer to «VALVE GUIDES, CHECKING»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-guides-checking) .
17. Exhaust Valve Do not grind, only lapping is permitted. Valve dimensions, refer to «VALVE DIMENSIONS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-dimensions) . Checking valve guides, refer to «VALVE GUIDES, CHECKING»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-guides-checking) .
18. Sealing Plugs Replace Installing , refer to «CAMSHAFTS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__camshafts) .
19. Intake Camshaft Removal and installation, refer to «CAMSHAFTS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__camshafts) . Check radial clearance using Plastigage (roller rocker lever removed). Wear limit: 0.1 millimeter (mm) Runout: Max. 0.035 mm Axial clearance: Max. 0.17 mm
20. Exhaust Camshaft Removal and installation, refer to «CAMSHAFTS»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__camshafts) . Check radial clearance using Plastigage (roller rocker lever removed). Wear limit: 0.1 mm Runout: Max. 0.035 mm Axial clearance: Max. 0.17 mm

VALVE DIMENSIONS

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

FASTENER TIGHTENING SPECIFICATIONS

Cylinder Head Cover Bolt Tightening Sequence and Specification

Tighten the cylinder head cover bolts -1 through 16- in the sequence shown to 10 Nm.

Cylinder Head Bolt Tightening Sequence and Specification

Scheme 10

Then tighten the cylinder head bolts -1 through 12- in the sequence shown as follows

Then tighten the bolts -13- to 10 Nm.

Guide Frame Bolt Tightening Sequence and Specification

Scheme 11

Tighten the NEW bolts -1 through 7- to 8 Nm in the sequence shown.

After that, continue to tighten all bolts an additional 90° (1/4) turn.

VALVE TIMING, CHECKING

Special tools and workshop equipment required

1. Camshaft clamp T40070

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Lock the crankshaft for checking the valve timing. Refer to CRANKSHAFT, LOCKING TO CHECK/ADJUST VALVE TIMING .

Valve Timing is Correct

Valve timing is correct when the bolts for the T40070 can be installed easily into camshafts as shown. Support surfaces of the T40070 must lie flat on the flats of the camshafts when doing this.

If the bolts could not be installed easily, attempt to rotate the exhaust camshaft at the recess using an open end wrench -A- (18 or 19 millimeter (mm), depending on wrench width) slightly in the -direction of the arrow- in order to eliminate any play in the chain drive.

If the bolts for the T40070 can now be installed easily with the chain drive tensioned in this manner, the valve timing is also correct. Possibly the crankshaft was not secured correctly.

Valve Timing is Not Correct

Valve timing is not correct when the bolts for the T40070 cannot be installed easily into the camshafts despite the tensioned chain drive.

1. In this case, the valve timing must be adjusted. Refer to «VALVE TIMING, ADJUSTING»(/volkswagen/new-beetle/a4-2005-2011/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-bpr-bps-hatchback__valve-timing-adjusting) .

Assembly

Assembly is performed in the reverse order of removal. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt (30 Nm).

COMPRESSION, CHECKING

Special tools and workshop equipment required

1. Spark plug removal tool 3122B
2. Ignition coil puller T40039
3. Torque wrench (5-50 Nm) VAG 1331
4. Compression tester VAG 1763
5. Adapter VAG 1381/5A

Conditions

1. Engine oil temperature must be at least 30 °C (86 °F).
2. Voltage supply OK.

Remove the engine cover.

Disconnect the connectors from the fuel injectors.

Remove the ignition coils with power output stages. Refer to IGNITION COILS WITH POWER OUTPUT STAGES .

Remove the spark plugs using 3122B.

Check the compression using VAG 1763 and VAG 1381/5A.

Note. Using the tester, refer to operating instructions.

Have a second technician operate the starter.

Operate the starter until the tester shows no further pressure increase.

Compression Pressure

To conclude work, erase the Diagnostic Trouble Code (DTC) memory of the Engine Control Module (ECM) since malfunctions were stored by disconnecting the connectors. Refer to ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING .

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial gauge holder MP 3-447
2. Dial gauge

Insert a new valve into the guide. The valve stem tip must seal with the guide. Due to differences in valve stem diameters, make sure that only intake valves are used to check the intake valve guides, and only exhaust valves are used to check the exhaust valve guides.

Scheme 12

Determine tilt clearance.

Wear limit: 0.8 millimeter (mm)

If tilt clearance is exceeded

Replace the cylinder head.

CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331

Removing

Remove the engine cover.

Disconnect the air hose for the crankshaft housing ventilation -arrow-.

Scheme 13

Remove the Secondary Air Injection (AIR) connecting pipe -A-.

Remove the ignition coils -1 through 5-. Refer to IGNITION COILS WITH POWER OUTPUT STAGES .

Remove the cylinder head cover bolts in sequence -16 through 1-.

Installing

Install in reverse order of removal. When doing this note the following

Note. Replace the cylinder head cover if damaged or leaking.

Clean the sealing surfaces so they are completely free of any oil or grease.

Tighten the cylinder head cover bolts in sequence -1 through 16-.

Observe the tightening sequence when installing the AIR connecting pipe -A-. (Scheme 15)

Scheme 14

Tightening Specifications

CHAIN COMPARTMENT COVER

Special tools and workshop equipment required

1. Trim removal wedge 3409
2. Torque wrench (5-50 Nm) VAG 1331
3. Hand drill with plastic brush attachment
4. Protective eyewear
5. Silicone sealant D 174 003 A2

Removing

Remove the engine cover.

Remove the battery. Refer to Removal and Installation .

Remove the battery holder bolts -arrows- and remove the battery holder from the vehicle.

Scheme 15

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the intake manifold. Refer to INTAKE MANIFOLD .

Remove the coolant pipe at the coolant thermostat housing and vacuum pump bracket.

Remove the retaining clip -arrow- and remove the coolant pipe -A-.

Scheme 16

Disconnect connectors -1 and 3-.

Scheme 17

Disconnect the pressure pipe -2- from the Secondary Air Injection (AIR) valve.

Remove the rear coolant pipe -4-.

Disconnect the vacuum hose -6- from the vacuum pump and disconnect the connector -7-.

Remove the brackets -8 and 9- and set the wiring harness with pressure pipe aside.

Press the bracket for the knock sensor wiring harness at the AIR valve slightly toward the rear.

Remove the coolant distribution housing -5- and set it aside with the coolant hoses connected.

Remove all the bolts for the chain compartment cover.

Pry off the chain compartment cover -1- uniformly from the cylinder head -2- at the top and bottom recesses.

Scheme 18

Note. Sealing surfaces must not be damaged under any circumstances. If necessary, use the 3409. After removing the chain compartment cover, clean the 3409 which is intended for the removal of interior parts.

Installing

Remove the remainder of sealant from the chain compartment cover and from the cylinder head using a rotating plastic brush.

Clean the coolant connection on the cylinder head, see -item 12- in COOLING SYSTEM COMPONENTS, ENGINE SIDE . If necessary, remove coolant deposits with a copper wire brush or fine sandpaper (minimum 100 grit). If the connection is worn, replace it using locking fluid D 000600 A2.

Replace the seal in the chain compartment cover. Refer to CHAIN COMPARTMENT COVER SEAL .

Replace the seal in the coolant thermostat housing.

Clean the sealing surfaces so they are completely free of any oil or grease.

Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).

Scheme 19

Note. The chain compartment cover must be installed within 5 minutes after application of sealant.

Apply the sealant bead -A- as shown to a clean sealing surface of chain compartment cover.

Scheme 20

1. The sealant bead must be 1.5 to 2.0 mm thick.

Coat the seal of the chain compartment cover lightly with engine oil and slide the chain compartment cover onto the coolant connection.

Install all bolts and tighten them in a diagonal sequence.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Install the battery. Refer to «Removal and Installation»(/volkswagen/new-beetle/a4-2005-2011/remont/charging-system/#battery-starter-generator-cruise-control-hatchback) .
2. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

Tightening Specifications

CHAIN COMPARTMENT COVER SEAL

Special tools and workshop equipment required

1. Arbor VW 195
2. Tube 60 mm dia. VW 415A
3. Fitting sleeve 3241/4

Conditions

1. Chain compartment cover removed

Scheme 21

Scheme 22

Support the chain compartment cover with supports -arrows- on a firm surface and press in the new seal until seated.

Special tools and workshop equipment required

1. Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
2. Torque wrench (5-50 Nm) VAG 1331
3. Torque wrench (40-200 Nm) VAG 1332
4. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
5. Polydrive bit and drive socket T10070 or Polydrive key 3452
6. Ignition coil puller T40039
7. Silicone sealant D 174 003 A2

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the engine cover.

Remove the plenum chamber cover. Refer to Removal and Installation .

Remove the battery. Refer to Removal and Installation .

Remove the battery holder bolts -arrows- and remove the battery holder from the vehicle.

Remove the intake manifold. Refer to INTAKE MANIFOLD .

Install the transport strap again onto the cylinder head to be able to hold the cylinder head during removal.

Remove the chain compartment cover. Refer to CHAIN COMPARTMENT COVER .

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Secure the camshafts and remove the sprocket and actuator from the camshafts. Refer to VALVE TIMING, ADJUSTING .

Hold the timing chain -A- as shown to be able to lay it under the coolant connection -arrow-.

Scheme 23

Remove the bolts -1 and 3- and remove the exhaust manifold brace -2-.

Scheme 24

Loosen the nuts for the double clamp.

Remove the 4 front exhaust pipe to the exhaust manifold nuts -1- and the suspended mount bolts -3-.

Scheme 25

Remove the front exhaust pipe -2- from the manifold and tie up firmly to the side.

Note. The flex joint in the front exhaust pipe must not be bent more than 10 degrees, otherwise it may be damaged.

Disconnect the harness connector -2- for the oxygen sensor in the exhaust manifold.

Scheme 26

Remove the heat shield at the top of the front exhaust pipe and free up the wiring harness of the oxygen sensor in the exhaust manifold to the engine.

Remove the wire bracket -3- bolts -arrows- at the Secondary Air Injection (AIR) valve.

Scheme 27

Remove the cylinder head bolts in the sequence specified.

Scheme 28

Note. If the bolt -2- was not able to be pulled out using a magnet, loosen the bolts for the T40070 one rotation, slide the T40070 toward the right front (seen in direction of travel) and tighten the bolts again. A second mechanic is required to remove and install the cylinder head.

Carefully remove the cylinder head.

Installing

Note. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Only remove the new cylinder head gasket from its packaging immediately before installing. Handle the new gasket with extreme care. Damaging will lead to leaks. Replace the cylinder head bolts.

Stuff clean cloths into the cylinders and chain compartment so that no dirt or abrasive powder can penetrate between the cylinder wall and piston and into the chain compartment.

Do not allow dirt or abrasive powder to get into coolant either.

Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper below 100 grit).

Carefully remove any metal particles, emery remains and the cloths.

Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).

Note the shelf life date.

Apply a bead of sealant -1- (front and rear) on the clean sealing surfaces as shown in figure.

Scheme 29

1. The sealant bead must be 2.0 to 2.5 mm thick.

Install the new cylinder head gasket -2-.

Note the alignment pins in the cylinder block -arrows-.

Scheme 30

Apply a bead of sealant -3- (rear only), as shown in figure, on the cylinder head gasket.

1. The sealant bead must be 2.0 to 2.5 mm thick.

Note. The cylinder head must be installed within 5 minutes of applying the sealant.

Install the cylinder head.

Guide the timing chain over the coolant connection.

Install the cylinder head bolts and tighten them hand tight.

Tighten the cylinder head bolts -1 through 12- in the sequence shown as follows

Then tighten the bolts -13- to 10 Nm.

Wipe off any sealant, which has leaked out.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt.
2. Install the battery. Refer to «Removal and Installation»(/volkswagen/new-beetle/a4-2005-2011/remont/charging-system/#battery-starter-generator-cruise-control-hatchback) .
3. Replace and fill coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

VALVE STEM SEALS

(with cylinder head installed)

Special tools and workshop equipment required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Adapter T40012
5. Torque wrench (5-50 Nm) VAG 1331
6. Valve cotters asm/disasm device VAS 5161
7. Guide plate for FSI engine VAS 5161/19B

Removing

To remove the valve stem oil seals, the following components must be removed as follows

1. Intake valves cylinder 1: Transport strap
2. Intake valves cylinder 5: Camshaft adjustment valve 1 -N205
3. Exhaust valves cylinder 5: Secondary Air Injection (AIR) solenoid valve -N112

Remove the plenum chamber cover Removal and Installation .

Remove the camshafts. Refer to CAMSHAFTS .

Remove the roller cam follower and set it down on a clean surface. Make sure that the roller cam followers are not interchanged.

Using the 3122B, remove the spark plugs.

Install the VAS 5161/19B with the VAS 5161/12 onto the cylinder head as shown.

Scheme 31

Adjust the piston of the respective cylinder to the Bottom Dead Center (BDC) position.

Install T40012 into the spark plug hole and connect a compressed air hose of at least 6 bar positive pressure.

Using the VAS 5161/3 and a plastic mallet, tap loose any stuck valve keepers.

Scheme 32

Install the VAS 5161/6 with the VAS 5161/5 into the VAS 5161/19B.

Scheme 33

Insert the VAS 5161/8 into the VAS 5161/19B.

Engage the VAS 5161/2 on the VAS 5161/6.

Note. On the exhaust side, VAS 5161/2 must be engaged as shown.

Press down the VAS 5161/8. At the same time, turn the knurled bolt for the VAS 5161/8 clockwise until the points engage in the valve keepers.

Lightly move the knurled bolt of the VAS 5161/8 back and forth, this causes the valve keepers to be pressed apart and captured in the VAS 5161/8.

Release the VAS 5161/2.

Remove the VAS 5161/8, valve spring retainers and valve springs.

Remove the valve stem seal using 3364.

Scheme 34

In the event the 3364 cannot be used due to limited space constraints, drive out the spring dowel sleeve -arrow- using a drift and remove the impact device.

Scheme 35

Place the lower part of the 3364 onto the valve stem oil seal.

Scheme 36

Insert a drift -1- into bore in 3364.

Using the drift -1- as a lever, pull out the valve stem oil seal -arrow-.

Installing

Place the plastic sleeve -A- on the valve stem to prevent damage to the new valve stem oil seal -B-.

Scheme 37

Oil the sealing lip of valve stem oil seal -B-, insert in into the 3365 and carefully slide it onto the valve guide.

Remove the plastic sleeve -A-.

Install the valve spring and valve spring retainer.

Install the VAS 5161 as shown.

Scheme 38

Note. If the valve keepers were removed from the VAS 5161/18, they must be inserted into the VAS 5161/18 next. Press the VAS 5161/8 onto the insertion device from above and take up valve keepers.

Press down the VAS 5161/8 using VAS 5161/2, tap lightly against the VAS 5161/8 in the lower area, rotate the knurled bolt for the VAS 5161/8 back and forth and pull upward while doing this.

Release the VAS 5161/2 with the knurled bolt pulled.

Remove the VAS 5161.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt.
2. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

CAMSHAFTS

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Hand drill with plastic brush attachment
3. Protective eyewear
4. Sealant D 154 103 A1

Removing

Note. Sealing surfaces on the bottom of the guide frame and top of the cylinder head must not be reworked. Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide frame, chain sprockets of camshafts must be removed. If the guide frame was loosened, the sealing plugs must be replaced.

Secure the camshafts and remove the sprocket and actuator from the camshafts. Refer to VALVE TIMING, ADJUSTING .

Remove the T40070.

Remove the guide frame bolts evenly from the outside toward the inside and remove the guide frame.

Carefully remove the camshaft and place it on a clean surface.

Installing

Remove the remainder of sealant from the guide frame (out of the grooves as well) and from the cylinder head using a rotating plastic brush.

Clean the sealing surfaces, they must be free of oil and grease.

Oil the journal surfaces of the camshafts.

Place the guide frame on a soft surface.

Install the camshafts correctly into the guide frame.

Scheme 39

1. Intake camshaft with sensor wheel -2- points toward the Camshaft Position (CMP) sensor -G40- -1-.
2. Camshafts must lie exactly in the axial bearings -3- in the guide frame.
3. Seal ends -4 and 5- must point upward or downward, they must not point to the side under any circumstances.

With the camshafts installed in the guide frame, hold the camshafts firmly in place and turn over and install the guide frame.

Rotate the camshafts until the threaded holes -arrows- point upward.

Scheme 40

Check whether the camshafts still lie exactly in the axial bearings of the guide frame.

Install the T40070 as shown to the camshafts and tighten the bolts to 20 Nm.

Turn over the guide frame again.

Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).

Lightly apply an even bead of sealant into the clean grooves of the guide frame -1 through 8-.

Scheme 41

Width of sealant bead

1. Grooves -1 through 5- : approximately 3.0 mm
2. Grooves -6 through 8- : approximately 4.0 mm

Note. Sealant beads must be applied according to exact specifications, otherwise excess sealant could get into the camshaft bearings. Installing and securing the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces. Note the expiration date of the sealing compound.

Install the guide frame onto the cylinder head immediately.

Gently tighten the bolts from the inside working toward the outside in several stages.

Then tighten the bolts to 8 Nm in the sequence indicated.

After that, continue to tighten all bolts an additional 90° (1/4) further.

Sealant must bulge outward slightly, even in the area of chain compartment -arrows-.

Scheme 42

Wipe off the sealant on the sealing surface facing the chain compartment cover.

Carefully press in the sealing plugs -A- until they reach the end of the chamfer -arrows-.

Scheme 43

Note. If the sealing plug was pressed in too far, it must be pressed through and pressed in again up to the mark.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt (30 Nm).
2. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 44

Scheme 45

1. Spark plug removal tool 3122B
2. Ignition coil puller T40039
3. Compression tester VAG 1763
4. Spark plug removal tool 3122 B
5. Valve seal removal tool 3364
6. Valve stem seal driver 3365
7. Adapter T40012
8. Valve cotters asm/disasm device VAS 5161
9. Guide plate for FSI engine VAS 5161/19B
10. Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
11. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
12. Polydrive bit and drive socket T10070 or Polydrive key 3452
13. Trim removal wedge 3409
14. Adapter VAG 1381/5A

Scheme 46

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Torque wrench (40-200 Nm) VAG 1332
3. Locking pin T03006
4. Multipoint socket T10035
5. Counter hold tool T10172
6. Camshaft clamp T40070

Scheme 47

Special tools and workshop equipment required

1. Arbor VW 195
2. Tube 60 mm dia. VW 415A
3. Fitting sleeve 3241/4

See also:
• CRANKSHAFT, LOCKING TO CHECK/ADJUST VALVE TIMING
• CRANKSHAFT, LOCKING
• DRAINING AND FILLING
• INTAKE MANIFOLD AND ATTACHMENTS ASSEMBLY OVERVIEW => Hose for Crankcase Ventilation
• IGNITION COILS WITH POWER OUTPUT STAGES
• ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING
• Removal and Installation
• INTAKE MANIFOLD
• COOLING SYSTEM COMPONENTS, ENGINE SIDE
• Removal and Installation
• CHAIN COMPARTMENT COVER
• CYLINDER HEAD COVER
• VALVE TIMING, CHECKING
• CHAIN COMPARTMENT COVER SEAL
• CYLINDER HEAD
• CAMSHAFTS
• VALVE TIMING, ADJUSTING
• VALVE STEM SEALS
• VALVE GUIDES, CHECKING
• VALVE DIMENSIONS