2.0 Fsi

Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 12.2005
15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ If an exchange cylinder head is installed, all the contact sur‐

faces between the support elements, roller rocker fingers and
the running surfaces of the cam shaft must be oiled before the
cylinder head cover is installed.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ Renew cylinder head bolts.
♦ If the cylinder head is replaced, the entire coolant must also
be renewed.
Assembly overview - cylinder head ⇒ page 40
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Removing and installing cylinder head ⇒ page 43
Removing and installing toothed belt ⇒ page 49
Checking compression ⇒ page 58
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Passat 2006 ➤
1.1 Assembly overview - cylinder head
1 - 10 Nm
2 - Cylinder head cover
❑ Removing and installing
⇒ page 41 .
3 - Gasket
❑ Renew if damaged or
leaking
4 - Valve housing
5 - Oil filler cap
6 - Gasket
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7 - 4 Nm
8 - Gasket for cylinder head
cover
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15 - Seal
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16 - 10 Nm
17 - Housing
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18 - Gasket
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23 - Cylinder head gasket
❑ Renew
❑ Note installation position: Part No. towards cylinder head.
40 Rep. Gr.15 - Cylinder head, valve gear

Passat 2006 ➤
24 - 10 Nm
25 - Hall sender -G40-
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28 - 20 Nm
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❑ Observe sequence when loosening and tightening ⇒ page 43 .
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❑ Torque setting: 40 Nm + 1/2 turn (180°) further.
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Checking cylinder head for distortion
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– Use straight edge and feeler gauge to measure for distortion

at several points.
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♦ Max. permissible distortion: 0.1 mm
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1.2 Removing and installing cylinder head
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cover
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 5024 A-
♦ Puller -T40039-
1. Cylinder head 41
Passat 2006 ➤
Removing
– Remove engine cover/air filter ⇒ page 175 .
– Unscrew bolts -arrows-.
– Remove ignition coils with output stages ⇒ page 199 . n AG. Volkswagen AG do
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– Separate wires -2, 3 and 4- from cylinder head cover.
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– Remove valve housing from cylinder head cover -arrows-. yri
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Continuation for all vehicles:
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– Unscrew crankcase breather line with heat shield from turbo‐

charger -1-.
– Remove activated charcoal filter line to turbocharger from cyl‐
inder head cover -2-.
– Loosen cylinder head cover working from outside to inside.
– Remove cylinder head cover.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
Renew cylinder head cover gaskets if damaged.

Passat 2006 ➤
– Tighten cylinder head cover in several stages in tightening se‐

quence as shown.
– Ensure the upper toothed belt guard is correctly fitted.
Torque settings
Component Nm
Cylinder head cover to cylinder head 10
Toothed belt guard to cylinder block 10 8)
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♦ Drip tray -V.A.G 1306-
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♦ Spring-type clip pliers -VAS
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♦ Special wrench, long reach rrectness of i
-T10070- or Polydrive key
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1. Cylinder head 43
Passat 2006 ➤
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical ewiring
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Removing cylinder head ⇒ page 44
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Installing cylinder head ⇒ page 47
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• The engine must be no more than warm to touch.
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♦ All cable ties which are released or cut open when removing
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♦ If engine oil is dirty, change oil ⇒ Maintenance ; Booklet 18.1 .
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– First check whether a coded radio is fitted. If so, obtain anti-

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– Disconnect earth strap at battery with ignition switched off ⇒

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– Remove windscreen wiper arms and plenum chamber cover Cop py
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– Remove intake manifold ⇒ page 177 .
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– Drain coolant ⇒ page 101 .
– Remove right wheel housing liner front part.
– Remove catalytic converter together with front exhaust pipe
⇒ page 195 .

Passat 2006 ➤
– Pull charge air hose -arrow- off charge air cooler.
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– Unscrew bolts -arrows- andlksremove
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– Unbolt oil supply line and coolant supply line from turbocharg‐
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1. Cylinder head 45
Passat 2006 ➤
– Remove bolts -1- and -2- and remove support for turbocharg‐
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– Remove coolant hoses -1- and -2-.
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– Pull off or disconnect all other electrical connections as nec‐
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– Unscrew cable retainer and place wiring harness to side.

Passat 2006 ➤
– Unscrew coolant flange -arrows-.

– Remove poly-V-belt ⇒ page 18 .
– Remove locking pin -T10060A- from tensioner for poly-V-belt.
– Remove toothed belt ⇒ page 49 .
– Remove cylinder head cover ⇒ page 41 .
– Keep to sequence when loosening

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♦ There must be no oil or coolant in the cylinder head bolt pock‐

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♦ Do not remove new cylinder head gasket from its packing until
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– Place clean cloths in cylinders so that no dirt or emery cloth
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– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.
– If crankshaft has been turned in the meantime, position No. 1
cylinder piston to TDC and then turn crankshaft back slightly.
– Fit new cylinder head gasket. Lettering (Part No.) must be
readable.
1. Cylinder head 47
Passat 2006 ➤ AG. Volkswagen AG d
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– Observe centring pins in cylinder ris
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– Insert cylinder head bolts and tighten hand-tight.
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Stage Tightening
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1 – Tighten with torque wrench to 40 Nm.

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2 – Turn 90° (1/4 turn) further using a rigid wrench.
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3 – Turn 90° (1/4 turn) further using a rigid wrench.
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– Install toothed belt ⇒ page 49 .
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Filling with new coolant ⇒ page 101 .

Passat 2006 ➤
1.4 Removing and installing toothed belt

equipment required
♦ Support bracket -10 - 222
A-
♦ Rack -10 - 222 A /1-
♦ Bracket -T10338-
1331-
1332-
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To remove engine bracket, lift engine a considerable amount with

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support bracket -10-222A- . Disconnect drive shafts from gearbox

to prevent damage through extreme bending angles.
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Remove toothed belt ⇒ page 49

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Install toothed belt ⇒ page 54

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1. Cylinder head 49
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The fuel supply line is under pressure! Wear eye protection and
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For safety reasons, fuse No. SD34 must be removed from fuse
holder on right in dash panel before opening the fuel system.
Otherwise the fuel pump will be activated by driver door contact
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switch.
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– Disconnect vacuum line -1- (only engine code BPY), breather
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line -2- and fuel supply line -3-. Do this by operating release
buttons.
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– Open the coolant expansion tank to release pressure and cted agen
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close again.
– Loosen clip -arrow- and separate coolant hose. Collect es‐

caping coolant with a cloth.
– Pull off connector -1-. Detach coolant expansion tank and

move clear to one side.
– Remove poly-V-belt ⇒ page 18 .

Passat 2006 ➤
– Unscrew tensioner for poly-V-belt -A- and secure bracket -

T10338- to the two upper threaded holes.
– Remove stop buffers for bonnet -arrows-.
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– Fit support bracket -10-222A- with rack -10-222A/1- on wing G. Volkswagen
edges as shown. Take up weight of engine in its installation
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Ensure that the wing edges are not damaged.
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– Remove securing bolts from assembly mounting/engine

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1. Cylinder head 51
Passat 2006 ➤
– Remove right wheel housing liner front part.
– Set camshaft sprocket to TDC marking by turning crankshaft.

The marking on camshaft toothed belt pulley must align with
arrow on toothed belt guard.
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– Unscrew bolts from toothed belt guard lower part -arrows-.

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Passat 2006 ➤
– Remove lower bolt -3-.

– Loosen bolts of right wheel housing liner and push to side.
– Remove bolt -1- through hole in wheel housing.

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– Loosen front exhaust pipe with catalytic converter from turbo‐ t to the co
charger -arrows-.
– Pull catalytic converter from turbocharger.
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– Unscrew bolts -2- and -3- at pendulum support.

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– Disconnect drive shafts from gearbox ⇒ Running gear, axles,
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1. Cylinder head 53
Passat 2006 ➤
4-cylinder injection engine (2.0AlGengine,
. Volkswagturbocharger)
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When raising engine using support bracket -10-222A- , ensure
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that no components or hoses are damaged, strained or torn
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– Raise engine with support bracket -10-222A- until upper bolt

-2- of engine bracket can be loosened and removed.
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– Raise engine further until the engine bracket can be removed

from above.
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– Unscrew remaining bolts from toothed belt guard -arrows- and
remove toothed belt guard from engine.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
– Turn crankshaft back slightly.
1.4.2 Installing toothed belt
Note
♦ When camshaft is turned, crankshaft must not be at TDC.

Danger of damage to valves and piston crowns.
♦ The engine must be no more than warm to touch.
– Place toothed belt on crankshaft toothed belt pulley (observe

direction of rotation).
– Secure toothed belt guard lower part with the two lower bolts.
– Install vibration damper / pulley with new bolts. Torque setting:
10 Nm + turn 90° further.

Passat 2006 ➤
– Turn crankshaft and camshaft to TDC No. 1 cylinder

-arrows-.
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– Tension toothed belt. To do so, turn hexagon key at the ec‐

centric adjuster clockwise (direction of arrow) until the notch
is above the indicator (toothed belt over-tensioned).
– Then release tension on toothed belt.
– Now tension toothed belt until the notch and the indicator are
aligned.
– Tighten securing nut to 25 Nm.
– Turn crankshaft two turns in direction of engine rotation and
set again to TDC. It is important that the last 45° of rotation
(1/8 turn) is performed without interruption.
– Check toothed belt tension again. Specification: Indicator and
notch must align.
1. Cylinder head 55
Passat 2006 ➤
– Check valve timing again.

If marks do not align:
– Repeat adjustment of valve timing.
If marks align:
– Install toothed belt guard -arrows-.
cardiagn.com
– Install engine support on cylinder block from above and tighten
bolts hand-tight.
Note agen
AG. Volkswagen AG d
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Note different bolt lengths. Bolt -3- is about 25 mm ris shorter than
ed
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bolts -1 and 2-. aut
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– Lower engine with support bracket -10-222A- until it is possible

un
pt
an
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to tighten the centre bolt -1- through the hole in the wheel
itte
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housing.
rm
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– Tighten all securing bolts to 45 Nm.

ot
wit
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– Install engine assembly mounting. Torque settings

hole
spec
⇒ page 12 .
es, in part or in w
t to the co
– Tighten bolts for engine assembly mounting and engine brack‐

et hand-tight -arrows-; to do so, bring surfaces into contact
using support bracket -10 - 222 A- .
rrectness of i
– Align engine bracket as follows:

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Rep. Gr.15 - Cylinder head, valve gear Prote AG.
Passat 2006 ➤
♦ There must be a distance of -a- at least 10 mm between engine

support and longitudinal member (right-side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
– Tighten bolts for engine assembly mounting and engine brack‐
et. Torque setting: 60 Nm + 90° (1/4 turn) further.
– Remove support bracket -10 - 222 A- .
– Remove bracket -T10339- and install tensioner for poly-V-belt.
– Install poly-V-belt ⇒ page 18 .
– Reconnect fuel lines and breather lines. Ensure push-on con‐
nectors are properly secured.
– Install coolant expansion tank.
– Install noise insulation tray ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Body front; Noise insulation .
– Install stop buffers for bonnet -arrows-.

– Refit fuse SD34 in fuse holder.
cardiagn.com
– Install engine cover/air filter.
AG. Volkswagen AG d
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1. Cylinder head 57
Passat 2006 ➤
1.5 Checking compression

equipment required
♦ Spark plug spanner -3122
B-
♦ Puller -T40039-
1331-
♦ Compression tester -V.A.G
1763-
♦ Adapter -V.A.G 1381/5A-
cardiagn.com
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Test prerequisite:
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• Engine oil temperature must be at least 30 °C.

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• Voltage supply OK.

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– Remove ignition coils with output stages ⇒ page 199 .
Co
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– Remove spark plugs using spark plug socket and extension
ht
pyri by
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-3122 B- .
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Prote AG.
– Check compression using compression tester -V.A.G 1763-
and adapter -V.A.G 1381/5A- .
Note
Using the compression tester ⇒ operating instructions .
– Have a second mechanic operate the starter.

– Operate starter until tester shows no further pressure in‐
crease.

Passat 2006 ➤
Compression pressures:
Engine code New Wear limit Permissible
pressure in bar bar difference be‐
tween cylin‐
ders
bar
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– After completing work, readautfault
h memory of engine control eo
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unit, erase all incorrect entries
ss that have been created during c
checks and repairs.
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If the fault memory was erased, the readiness code must be gen‐
hole
erated ⇒ Vehicle diagnosis, testing and information system VAS
spec
5051 “Guided functions”.
es, in part or in w
t to the co
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Prote AG.
1. Cylinder head 59
Passat 2006 ➤
4-cylinder injection engine (2.0 l engine,
waturbocharger)
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AG do 12.2005
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♦ Cylinder heads which have cracks between the valve seats or ot p
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between a valve seat insert and the spark plug thread can be
, is n
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used further without reducing service life, provided the cracks
hole
spec
do not exceed a maximum of 0.3 mm in width, or when no more
es, in part or in w
than the first 4 turns of the spark plug thread are cracked.
t to the co
♦ Cylinder head and retaining frame must only be renewed to‐
gether.
rrectness of i
♦ Wait about 30 minutes after installing the camshafts before
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starting the engine. Hydraulic valve compensation elements

have to settle (otherwise valves will strike pistons).
nform
ercia
♦ After working on the valve gear, turn the engine carefully at

least 2 rotations to ensure that none of the valves make con‐
m
at
tact when the starter is operated.
om
ion
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♦ Always renew gaskets and seals.

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Assembly overview - valve gear ⇒ page 61 .
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Valve dimensions ⇒ page 62
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Checking valve guides ⇒ page 62
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Renewing valve stem oil seals ⇒ page 63
cted agen
Prote AG.
Renewing exhaust camshaft seal ⇒ page 67

Removing and installing camshaft adjuster ⇒ page 69
Removing and installing inlet camshaft control valve 1 -N205-
⇒ page 73
Removing and installing camshafts ⇒ page 74 .

Passat 2006 ➤
2.1 Assembly overview - valve gear
1 - 65 Nm
2 - Camshaft toothed belt pul‐
ley
❑ Use counter-hold tool
-3036- to loosen and
tighten.
3 - Seal
❑ Renewing ⇒ page 67
4 - Cylinder head AG. Volkswagen AG d
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5 - Valve guide byV
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❑ Checking ⇒ page 62 horis nte
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6 - Valve stem oil seal ss c
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❑ Renewing ⇒ page 63
pt
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7 - Valve spring
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8 - Upper valve spring plate
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9 - Cotters
hole
spec
10 - Hydraulic valve clearance
es, in part or in w
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compensation element
❑ Do not interchange
❑ Oil contact surfaces
rrectness of i
11 - Woodruff key
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❑ Check for secure seat‐

ing
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12 - Exhaust camshaft
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❑ Check radial clearance

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with plastigage (roller

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rocker fingers re‐

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❑ Run-out: max. 0.035
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13 - Retaining frame by c lksw
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❑ With integrated camshaft bearings.
❑ Clean sealing surface; machining not permitted
❑ Remove sealant remnants
14 - 8 Nm + 1/4 turn (90°) further
❑ Renew.
15 - Variable camshaft timing adjuster
❑ Removing and installing ⇒ page 69 .
16 - 20 Nm + 1/8 turn (45°) further
❑ Use counter-hold tool -3036- to loosen and tighten.
17 - Inlet camshaft
❑ Check radial clearance with plastigage, wear limit: 0.1 mm.
❑ Run-out: max. 0.035 mm.
18 - Chain tensioner
❑ Secure with locking pin -T10115- before removing.
2. Valve gear 61
Passat 2006 ➤
19 - Drive chain
❑ Removing and installing ⇒ page 69 .
❑ Check for wear.
20 - 10 Nm
21 - 10 Nm AG. Volkswagen AG d
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22 - Hall sender -G40- d by Vo gu
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23 - Exhaust valve utho eo
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❑ Do not rework. Only lapping in is permitted. ss c
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❑ Valve dimensions ⇒ page 62
pt
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❑ Checking valve guides ⇒ page 62
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24 - Inlet valve
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❑ Do not rework. Only lapping in is permitted.
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❑ Valve dimensions ⇒ page 62
spec
es, in part or in w
❑ Checking valve guides ⇒ page 62
t to the co
25 - Cap
❑ Renew
rrectness of i
cardiagn.com
❑ Removing: pierce centre of cap using screwdriver and lever out.
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❑ Installing: do not use sealant. Press in 1...2 mm using thrust piece -3334- .
nf
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2.2 Valve dimensions
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Inlet and exhaust valves must not be machined. Only lapping-in
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Dimension Inlet valve Exhaust valve
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∅a mm 33.75...33.95 27.90...28.10
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Prote AG.
α ∠° 45 45
2.3 Checking valve guides

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge

Passat 2006 ➤
– Insert new valve in guide. End of valve stem must be at same

height as guide. Due to differences in stem diameters, use only
an inlet valve in inlet guide and an exhaust valve in exhaust
guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded:
– Renew cylinder head.
2.4 Renewing valve stem oil seals

(with cylinder head installed)

equipment required
♦ Spark plug spanner -3122
cardiagn.com
B- AG. Volkswagen AG d
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♦ Valve stem seal puller ised b ara
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-3364- hor eo
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♦ Valve stem oil seal fitting s
ce
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tool -3365-
nl
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♦ Adapter -T40012-
erm
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ility
ot p
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1331-
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♦ Dismantling and assem‐

spec
es, in part or in w
bling device for valve cot‐

ters -VAS 5161- t to the co
♦ Guide plate -VAS 5161/19-

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Prote AG.
Removing valve stem oil seals ⇒ page 63 .

Installing valve stem oil seals ⇒ page 65 .
2.4.1 Removing valve stem oil seals

– Removing camshafts ⇒ page 74 .
2. Valve gear 63
Passat 2006 ➤
– Remove roller rocker fingers and place onto a clean surface.

When doing so, make sure that roller rocker fingers are not
interchanged.
– Remove spark plugs with spark plug socket -3122 B- .
– Secure guide plate -VAS 5161/19- with knurled screws -VAS
5161/12- to cylinder head as shown.
– Set piston of respective cylinder to “bottom dead centre”.
– Screw adapter -T40012- into spark plug thread and connect
compressed air of at least 6 bar.
– Knock loose sticking valve cotters using punch -VAS 5161/3-

and a plastic-headed hammer.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
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erm
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– Screw snap-in device -VAS 5161/6- with engaging fork -VAS

ility
ot p
5161/5- into guide plate -VAS 5161/19- .

wit
, is n
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– Insert assembly cartridge -VAS 5161/8- into guide plate -VAS

hole
spec
5161/19- .
es, in part or in w
t to the co
– Attach pressure fork -VAS 5161/2- to snap-in device -VAS

5161/6- .
rrectness of i
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Note
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On the exhaust side, the pressure fork -VAS 5161/2- must be

o
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f
hooked in as shown.
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ng
t.
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– Press down assembly cartridge -VAS 5161/8- . Simultane‐
gh ht
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right until tips lock into valve cotters. Prote AG.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release the pressure fork -VAS 5161/2- .
– Remove assembly cartridge -VAS 5161/8- .

Passat 2006 ➤
– Pull off valve stem oil seals with puller 3364.
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– If puller 3364 cannot be used on account of restricted space,
an
itte
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knock out pin -arrow- using a drift and remove the impact ex‐
erm
ab
tractor attachment.
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– Place lower section of puller 3364 on valve stem oil seal.

orm
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– Insert a punch -1- through hole in lower section of puller.

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– Apply assembly lever to puller and pull out valve stem oil seal
or
thi
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-arrow-.
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Prote AG.
2.4.2 Installing valve stem oil seals

– To prevent damage to the new valve stem oil seals -B-, attach
plastic sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool -3365- and push carefully onto
valve guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Set up disassembly and assembly tool -VAS 5161- as shown.
2. Valve gear 65
Passat 2006 ➤
Inlet side
Exhaust side
cardiagn.com
Note
♦ If valve cotters have been removed from assembly cartridge,

they need to be put into insertion device -VAS 5161/18- first.
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and capture valve cotters. AG. Volkswagen AG d
agen oes
olksw not
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– Press down assembly cartridge -VAS 5161/8- ho riswith pressure nte
eo
fork -VAS 5161/2- and pull knurled screws aofut assembly car‐ ra
c
tridge up, at the same time turning it in both
s directions.
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nl
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– Release the pressure fork -VAS 5161/2- with knurled screw

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still in pulled-out position.

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ility
ot p
– Remove removal/installing device for valve cotters -VAS

wit
, is n
5161- .
h re
hole
Further assembly is basically the reverse of the dismantling pro‐

spec
cedure.
es, in part or in w
t to the co
– Installing camshafts ⇒ page 76 .

rrectness of i
l purpos
nform
mercia
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om
ion
c
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or
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ate
do
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cum
for
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ng
t.
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Cop py
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by lksw
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Prote AG.

Passat 2006 ➤
2.5 Renewing exhaust camshaft oil seal

equipment required
♦ Oil seal extractor -2085-
♦ Adapter -2085/2-
♦ Counter-hold tool -3036-
♦ Assembly tool -T10071-
♦ Two-arm puller -T40001-
with claw -T40001/6- and
claw -T40001/7-
1332-
cardiagn.com
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Removing seal ⇒ page 67 .

Installing seal ⇒ page 68 .
rrectness of i
2.5.1 Removing seal

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nform
ercia
– Loosen camshaft toothed belt pulley (using counter-hold tool

-3036- ).
m
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com
tion in
r
te o
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Prote AG.
2. Valve gear 67
Passat 2006 ➤
– Pull off camshaft toothed belt pulley using puller -T40001- ,

hook -T40001/6- and hook -T40001/7- .
– To guide seal extractor, screw adapter -2085/2- into camshaft

to stop by hand.
– Screw inner part of oil seal extractor -2085- two turns (approx.
3 mm) out of outer part and lock with knurled screw.
cardiagn.com
– Lubricate threaded head of oil seal extractor -2085- , place it
in position and exerting firm pressure, screw it as far as pos‐
sible into oil seal.
n AG. Volkswagen AG
– Loosen knurled screw and turnolinner
ksw part of extractor against
age does
not
camshaft until oil seal has dbeen
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2.5.2 Installing seal

spec
es, in part or in w
t to the co
– Remove oil residue from camshaft journal using a clean cloth.

– Mask off groove on taper of camshaft using commercial ad‐
rrectness of i
hesive tape (e.g. Sellotape).

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– Carefully push dry seal onto camshaft journal.

– Press oil seal in to stop using thrust piece -T10071- . To do
nform
ercia
this, use screw -T10071/4- .

m
– Insert parallel key into camshaft.

at
om
ion
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ate
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Prote AG.

Passat 2006 ➤
– Install camshaft toothed belt pulley. To tighten bolt, hold cam‐

shaft toothed belt pulley in position using counter-hold tool
-3036- . Torque setting: 65 Nm.
Note
♦ When turning the camshaft, the pistons must not be at TDC.

This could otherwise result in damage to valves and pistons.
♦ Ensure the parallel key is correctly seated.

– Install poly-V-belt ⇒ page 18 .
cedure.
2.6 Removing and installing camshaft adjuster
cardiagn.com
equipment required
♦ Special wrench, long reach
-T40080-
♦ Camshaft clamp -T10252-
olkswagen AG
en AG. V
♦ Locking pin -T10115-olkswag does
not
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♦ Pin wrench -T10020-
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♦ Torque wrench
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1332-
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es, in part or in w
t to the co
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nform
mercia
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tion in
r
te o
thi
s
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do
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fo
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ng
t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
Removing camshaft adjuster ⇒ page 70 .

Installing camshaft tensioner ⇒ page 71 .
2. Valve gear 69
AG. Volkswagen AG d
agen oes
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Passat 2006 ➤ d byV gu
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4-cylinder injection engine
horis (2.0 l engine, turbocharger) - Edition 12.2005
nte
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2.6.1 Removing camshaft adjuster
ce
le
un
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an
d
itte
– Remove high-pressure pump ⇒ page 136 .
y li
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ab
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– Remove cylinder head cover ⇒ page 41 . ot
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– Pull off coolant hoses -1 and 2-, unscrew bolt -3- and loosen
h re
hole
coolant pipe from heat shield.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Unscrew cable retainer -arrow-.
s
iva
do
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cum
fo
en
g
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n
t.
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Cop py
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rig ht
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Prote AG.
– Remove cover from camshaft adjuster -arrows-.
– Align mark on camshaft toothed belt pulley with mark on tooth‐

ed belt guard. The indentations -arrows- face each other.

Passat 2006 ➤
– Fit camshaft clamp -T10252- as shown and secure -arrows-.

– Loosen securing bolt from camshaft adjuster using socket in‐
sert -T40080- .
AG. Volkswagen AG d
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– Compress chain tensioner -arrow A- and lock orisewith locking pin nte
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-T10115- -arrow B-. auth
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– Remove securing bolt from camshaft adjuster and remove
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nl
pt
camshaft adjuster together with chain.
du
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ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
2.6.2 Installing camshaft tensioner
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• The camshafts are located with the camshaft clamp -T10252- .
nform
ercia
– Fit chain onto camshaft adjuster.

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Prote AG.
– Position camshaft adjuster in front of exhaust camshaft so that

notch -A- and pin -B- face each other.
2. Valve gear 71
Passat 2006 ➤
– Lay chain over inlet camshaft sprocket starting at top -arrow-

without changing its position.
– Turn inlet camshaft slowly in direction of arrow -A- using 2-hole

pin wrench -T10020- until the camshaft adjuster fits onto the
camshaft.
Note
If it is not possible to fit the pin into the notch: remove chain and
fit chain again.
cardiagn.com
– Tighten camshaft adjuster securing bolt to 20 Nm +1/8 turn
(45°) further. Use special wrench, long reach -T40080- for this
purpose.
– Remove locking pin -T10115- arrow -B-.

cedure. G. Volkswage nA n AG d
wage oes
– Installing high-pressure pump ⇒ page
y V 136 .
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Passat 2006 ➤
2.7 Removing and installing inlet camshaft control valve 1 -N205-

Special tools and workshop lkswage es n
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♦ Torque wrench -V.A.G autho
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♦ Torx bit set -V.A.G 1766-
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♦ Ratchet 1/4" -VAS 6234-
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♦ Spring-type clip pliers -
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Removing
– Pull off connector -1-.
– Loosen wiring harness -2- from retainer.
– Remove bolts -3-.
Note
Do not pull inlet camshaft control valve 1 -N205- out of connector.
2. Valve gear 73
Passat 2006 ➤
ks wage es n
– Unscrew bolts -arrows- and pull inlet camshaft control valve Vo1l ot g
by ua
-N205- out of housing. ris
ed ran
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♦ The inlet camshaft control valve 1 -N205- and housing must
wit
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be free of dirt and soiling.
h re
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spec
♦ Unpack the new inlet camshaft control valve 1 -N205- imme‐
es, in part or in w
diately prior to installation.
t to the co
Caution
rrectness of i
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♦ Ensure the inlet camshaft control valve 1 -N205- is pro‐

tected from knocks and impacts.
nform
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– Moisten O-ring with engine oil.
at
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– Carefully insert inlet camshaft control valve 1 -N205- into
in t
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housing and press vertically to valve rod onto stop by hand.

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– Tighten bolts to 4 Nm.
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2.8 Removing and installing camshafts
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♦ Two-arm puller -T40001-
♦ Counter-hold tool -3036-
Removing camshafts ⇒ page 75 .

Installing camshafts ⇒ page 76 .

Passat 2006 ➤
2.8.1 Removing camshafts agen

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♦ The sealing surfaces on bottom of retaining frame and top of
ce
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un
pt
cylinder head must not be reworked.
an
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♦ The camshaft bearings are integrated into the cylinder head
ab
pe
ility
and the retaining frame. The toothed belt must be relieved of
ot
wit
tension before the retaining frame is removed. , is n
h re
hole
♦ Renew camshaft oil seal and sealing cap if retaining frame has
spec
been unfastened.
es, in part or in w
t to the co
– Remove camshaft adjuster ⇒ page 69 .
rrectness of i
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– Loosen camshaft sprocket (using counter-hold tool -3036- ).
nform
mercia
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– Use puller -T40001- , claw -T40001/6- and claw -T40001/7- to
pull off camshaft sprocket.
– Remove rear toothed belt guard from cylinder head.
– Loosen retaining frame bolts evenly working from outside in‐
wards and remove retaining frame.
– Carefully lift out the camshafts and place them down on a
clean surface.
– Remove old sealant from groove in retaining frame and from

sealing surfaces.
– Prevent dirt and residual sealant from entering cylinder head.
2. Valve gear 75
Passat 2006 ➤
2.8.2 Installing camshafts
Note
♦ Sealing surfaces must be free of oil and grease.

♦ The pistons must not be positioned at TDC.
♦ Ensure that all roller rocker fingers contact the valve ends cor‐
rectly.
– Oil camshaft running surfaces.

– Insert camshafts carefully in the camshaft bearings of cylinder
head. Cams -A- of cylinder 4 must face each other.
AG. Volkswagen AG d
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ksw
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– Apply an even, slightly projecting sealant bead (D 154,103 A1)
itte
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into the clean groove of the retaining frame.
ab
ility
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, is n
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Note
hole
spec
es, in part or in w
♦ Sealant must not be applied too thickly. If necessary wipe

away excess sealant with a lint-free cloth. t to the co
♦ The retaining frame should be positioned and bolted on with‐
rrectness of i
out interruption because the sealant begins to harden imme‐

diately when the sealing surfaces come into contact with each
l purpos
other.
♦ Observe the use-by date of the sealing compound.
nf
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atio
– Place retaining frame on cylinder head.

om
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– Tighten bolts lightly in several stages, working from inside out‐

thi
te
wards.
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– Then tighten bolts in the sequence shown to 8 Nm 1/4 (90°) yi

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– Drive in sealing cap ⇒ Item 25 (page 62) about 1...2 mm using cop Vo
by lksw
thrust piece -3334- . cted agen
Prote AG.
– Install camshaft oil seal ⇒ page 68 .

– Install rear toothed belt guard.
– Insert parallel key into camshaft.

Passat 2006 ➤
– Install camshaft toothed belt pulley. To tighten bolt, hold cam‐

shaft toothed belt pulley in position using counter-hold tool
-3036- . Torque setting: 65 Nm.
Note
♦ When turning the camshaft, the pistons must not be at TDC.

This could otherwise result in damage to valves and pistons.
♦ Ensure the parallel key is correctly seated.

– Install camshaft adjuster ⇒ page 71 .
– Install cylinder head cover ⇒ page 41 .
cedure.
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urposes, in part or in wh
t to the co
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2. Valve gear 77

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Passat 2006 ➤

4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 12.2005

15 – Cylinder head, valve gear

♦ If an exchange cylinder head is installed, all the contact sur‐

Assembly overview - cylinder head ⇒ page 40

1.1 Assembly overview - cylinder head

❑ Removing and installing

14 - Cable retainer t to the co

40 Rep. Gr.15 - Cylinder head, valve gear

29 - Cylinder head bolt

– Use straight edge and feeler gauge to measure for distortion

– Separate wires -2, 3 and 4- from cylinder head cover.

– Remove activated charcoal filter line from cylinder head cover

– Unscrew crankcase breather line with heat shield from turbo‐

Renew cylinder head cover gaskets if damaged.

42 Rep. Gr.15 - Cylinder head, valve gear

– Tighten cylinder head cover in several stages in tightening se‐

♦ Drip tray -V.A.G 1306-

♦ Torque wrench -V.A.G

♦ Torque wrench -V.A.G

When doing any repair work, especially in the engine compart‐

must be fitted in the same position when installing.

– First check whether a coded radio is fitted. If so, obtain anti-

– Disconnect earth strap at battery with ignition switched off ⇒

Electrical system; Rep. Gr. 27 ; Disconnecting and connecting

44 Rep. Gr.15 - Cylinder head, valve gear

– Pull charge air hose -arrow- off charge air cooler.

– Unscrew cable retainer and place wiring harness to side.

46 Rep. Gr.15 - Cylinder head, valve gear

– Unscrew coolant flange -arrows-.

– Keep to sequence when loosening

and body have been detached.

– Remove cylinder head.

♦ There must be no oil or coolant in the cylinder head bolt pock‐

ets in the cylinder head.

immediately before installing.

♦ Handle new gasket with extreme care. Damage will cause

1 – Tighten with torque wrench to 40 Nm.

– Install cylinder head cover ⇒ page 41 .

Filling with new coolant ⇒ page 101 .

48 Rep. Gr.15 - Cylinder head, valve gear

1.4 Removing and installing toothed belt

Special tools and workshop

To remove engine bracket, lift engine a considerable amount with

support bracket -10-222A- . Disconnect drive shafts from gearbox

Remove toothed belt ⇒ page 49

Install toothed belt ⇒ page 54

1.4.1 Removing toothed belt

– Remove engine cover/air filter ⇒ page 175 .

– Disconnect vacuum line -1- (only engine code BPY), breather

Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and

– Loosen clip -arrow- and separate coolant hose. Collect es‐

– Pull off connector -1-. Detach coolant expansion tank and

50 Rep. Gr.15 - Cylinder head, valve gear

– Unscrew tensioner for poly-V-belt -A- and secure bracket -

– Remove stop buffers for bonnet -arrows-.

– Remove securing bolts from assembly mounting/engine

bracket -arrows- and remove complete assembly mounting.

– Remove noise insulation tray ⇒ General body repairs, exteri‐

or; Rep. Gr. 50 ; Body front; Noise insulation .

– Remove right wheel housing liner front part.

– Set camshaft sprocket to TDC marking by turning crankshaft.