Cylinder Head: Removing

WARNING: This page is about a different car, the 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.

CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

-- Release the high side fuel pressure. Refer to HIGH SIDE FUEL PRESSURE, RELEASING .

-- Turn off the ignition and all electric consumers and remove the key.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING .

-- Loosen the hose clamp -2-.

Fig 1: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

-- Disconnect the connector -arrow- and free up the electrical wire.

WARNING: Risk of scalding due to hot steam and hot coolant:

The coolant system is under pressure when the engine is warm.
Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

-- Open the coolant expansion tank cap.

-- Remove the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

-- Remove the noise insulation. Refer to NOISE INSULATION OVERVIEW .

-- Remove the right front wheel.

-- Remove the right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Remove the charge air hose by loosening the clamps -1 and 2-.

Fig 2: Air Cooler Air Duct

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-- Seal off the connection on the charge air cooler with a clean cloth.

-- Place the drip tray for VAS 6100 VAS 6208 under the engine.

NOTE: Collect any leaking coolant in a clean container for disposal or reuse.

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Remove the bolt -1- and remove the charge air pipe downward.

Fig 3: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolts -arrows-.

Fig 4: Air Guide Pipe And Bolts

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-- Remove the charge air pipe by lifting the clamps -1 and 2-.

-- Disconnect the connectors -1 and 2- and free up the wire -arrows-.

Fig 5: Identifying Turbocharger Electrical Connectors

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-- Remove the bolts -1 and 2- and remove the turbocharger support.

Fig 6: Identifying Turbocharger Support And Bolts

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-- Remove the banjo bolt -2- and move the coolant pipe to the side.

Fig 7: Identifying Oil Return Line, Coolant Line And Oil Supply Line Fasteners

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-- Remove the bolts -1- for the oil return pipe.

-- Remove the bolt -3- for the oil supply pipe.

-- Disconnect the camshaft adjustment valve 1 connector -1-.

Fig 8: Camshaft Adjustment Valve And Bolts

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-- Remove the ignition coils with output stages. Refer to IGNITION COILS WITH POWER OUTPUT STAGES , and lay the wiring harness to the side.

Fig 9: Crankcase Ventilation, Tightening Sequence

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-- Disconnect the hose for the crankcase ventilation - 1 -.

-- Remove the crankcase ventilation bolts -arrows-.

-- Remove the charge air pipe bolt -arrow-.

Fig 10: Identifying Charge Air Pipe Bolt And Hose Clamp

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-- Loosen the hose clamp -2- and remove the charge air pipe together with the crankcase ventilation.

WARNING: The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the fuel supply line -1- and the vent line -2-. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 11: Identifying Supply Line (Metal Coupling)

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-- Seal the lines so that the fuel system is not contaminated by dirt, etc.

-- Disconnect the coolant hose -arrow- from the expansion tank.

Fig 12: Disconnecting Coolant Line To Coolant Expansion Tank

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-- Remove the coolant hoses -arrows- from the coolant pipe.

Fig 13: Identifying Vacuum Line, Ground Wire And Bolt

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-- Remove the nut and ground wire -3- and remove the bolt -4-.

-- Disconnect the vacuum hoses -arrows-.

Fig 14: Identifying Vacuum Hoses

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-- Remove the bolts -1 though 3- and remove the heat shield and the coolant pipe.

Fig 15: Identifying Heat Shield Bolts

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Remove the bolt -2- from the heat shield using a 6 mm hex socket.

NOTE: The hex wrench -A- part of the socket must be at least 5 cm -B- long. A socket that tapers to 6 mm at the tip is too wide.

Fig 16: Identifying 6 mm Hex Socket, 5 cm Long

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-- Remove the banjo bolt and the oil supply pipe -4- from the turbocharger.

Fig 17: Identifying Heat Shield Bolts

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-- Disconnect the fuel pressure regulator valve connector -2-.

Fig 18: Fuel High Pressure Pump & Fuel Pressure Regulator Valve Electrical Harness Connector

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Engine Code CBFA

Fig 19: Identifying Secondary Air Injection (Air) Solenoid Valve N112 Connector And Hose

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-- Disconnect the connector -A- and hose -B- from the Secondary Air Injection (AIR) solenoid valve.

-- Loosen the coolant pipe by removing the bolts -arrows-.

Fig 20: Coolant Pipe And Bolts

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Continuation for All

-- Disconnect the coolant hose from the water connection on the cylinder head.

-- Disconnect the connectors -1 through 4-.

Fig 21: EVAP Filter Vacuum Hose, Electrical Connectors And Electrical Cable

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-- Free up the wire -5-.

-- Disconnect the Evaporative Emission (EVAP) canister vacuum hose -6-.

Fig 22: Identifying Vacuum Line And Electrical Connectors

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-- Disconnect the connector -1 - and pull the connectors out of the retainers.

-- Disconnect the connectors -2 through 4-.

-- Disconnect the coolant line from the intake manifold by the removing the bolts -arrows-.

Fig 23: Bracket Bolts

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-- Remove the intake manifold support by removing the nut -1- and bolt -2-.

Fig 24: Identifying Intake Manifold Bracket Mounting Nut & Bolt

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-- Remove the oil filter. Refer to OIL FILTER HOUSING/ACCESSORY BRACKET OVERVIEW .

-- Disconnect the coolant hoses -arrows- and move them to the side.

Fig 25: Coolant Hoses

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-- Remove the bolts -arrows- and remove the camshaft adjustment valve 1.

Fig 26: Camshaft Adjustment Valve And Bolts

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-- Remove the upper timing chain cover. Refer to Removing .

CAUTION: The control valve has a left hand threads.

-- Remove the control valve in the -direction of the arrow- using the assembly tool T10352.

Fig 27: Identifying Assembly Tool T10352 To Remove Control Valve

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-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 28: Bearing Bracket Bolts

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-- Rotate the vibration damper into the Top Dead Center (TDC) position -arrow- using the counter hold tool T10355:

Fig 29: Identifying Markings -1- On Camshafts Aligned To Point Upward

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The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.
The marks -1- on the camshafts must point upward.

-- Carefully mark the position of the drive chain to the sprockets -A arrows- with a waterproof marker. Also mark the position of the drive chain to the guide rail -B arrows-.

Fig 30: Identifying Position Marks: Drive Chain To Sprockets And Drive Chain To Guide Rail

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These marks are necessary for reinstallation later.

-- Remove the plug -arrow-.

Fig 31: Identifying Plug

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The locking wedge in the chain tensioner must be lifted in order to release the tension from the chain tensioner. Sand the end of a locking pin T40011 down to a point. A screwdriver with a head approximately 1.5 mm wide can also be used.

CAUTION: There is a risk of damaging the chain tensioner. Proceed very carefully.

-- Raise the locking wedge in the chain tensioner Insert the screwdriver in the chain tensioner bore in the -direction of arrow 1-.

Fig 32: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011

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-- In order to tension the chain tensioner, rotate the crankshaft opposite the engine rotation direction -2-. Secure the chain tensioner using the locking pin T40011.

NOTE: The intake camshaft switches in the engine direction rotation.

-- Remove the guide pin -1- and guide the tensioning rail -2- downward.

Fig 33: Guide Tensioning Rail, Upper Guide Rai And Bolt

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-- Remove the upper guide rail -3- by unlocking the latch (located in the center) with a screwdriver and pushing the guide rail forward.

-- Remove the camshaft timing chain from the sprockets.

CAUTION: Danger of damaging the valves, piston head and lower timing chain cover:

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.
Panels are installed on the lower timing chain cover to prevent the chain from falling down. The panels can bend if the crankshaft is rotated when the chain is loose.

-- Turn the sealing plugs -arrows- counterclockwise in the -direction of the arrow- 90° (1/4) turn and remove.

Fig 34: Ball Head And Sealing Plug

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-- Remove the ball studs -1 and 2-.

-- Remove the cap.

-- Remove the bolts -arrows-.

Fig 35: Cylinder Head Loosening Sequence

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-- Remove the cylinder head bolts in sequence -1 through 5- using the polydrive bit and drive socket T10070 until 2 are left.

NOTE:

To remove the cylinder head bolts, rotate the camshaft with a wrench if necessary.

Make sure all necessary electrical wires are loosened!

Pay attention to the tension and guide rails when lifting the cylinder head.

-- Install the engine support T10014 with each of the two small and large washers, as shown.

Fig 36: Identifying Engine Support -T10014-, Washers, Bolt And Engine Sling -2024 A-

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M8 washer, small.
M8 washer, large. The outer diameter of the washer must be larger than the hole in the bracket.
M8 x 30 bolt.

-- Install the engine sling 2024 A to the engine support T10014 and in the front left lifting eye on the cylinder head.

-- Connect the shop crane - load cap = 700-1200 KG to the engine sling 2024 A and gently tension the cylinder head.

Fig 37: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-

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-- Remove the last two cylinder head bolts.

CAUTION:

Carefully lift the cylinder head until the guide rail for the camshaft timing chain is free.
The tension and guide rails must not be damaged.

-- Lay the cylinder head on a soft surface, such as foam.