Cylinder Head: Removing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, and 2014 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

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

-- Remove the camshafts, refer to CAMSHAFT .

CAUTION:

Risk of damaging valves and piston crowns.

Do not turn the crankshaft if the camshaft has been removed.

-- Remove the catalytic converter, refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

-- Remove the Heated Oxygen Sensor -G39-, refer to HEATED OXYGEN SENSOR .

-- Loosen the hose clamp -3- and -5-.

Fig 1: Identifying Senors And Clamps

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-- Disconnect the connector from the Charge Air Pressure Sensor -G31- -arrow-.

-- Remove the bolts -1- and -4- and then remove the air guide pipe downward.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

-- Loosen the clamps -arrows- and remove the coolant hoses.

Fig 2: Identifying Clamps And Coolant Hoses

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-- Swing the coolant line -1- to the side.

-- Disconnect the connectors -arrow- for the Oil Pressure Switch - F1- -3-.

Fig 3: Identifying Oil Filter Housing, Oil Pressure Regulation Valve, Reduced Oil Pressure Switch And Connectors

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-- Disconnect the connectors -arrow- for the Reduced Oil Pressure Switch -F378- -2-.

-- Remove the bolts -arrows-.

Fig 4: Locating Air Guide Pipe Bolts

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-- Remove the bolt -1- and the nut -3- and then remove the bracket -2- for the intake manifold.

Fig 5: Identifying Bolt And Nut

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-- Disconnect the connectors:

Fig 6: Disconnect Connectors

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For the Throttle Valve Control Module -J338-
For the Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71-

-- Remove the connector -4- from the bracket.

-- Free up the wiring harness and push it to the side.

-- Loosen the hose clamp -3- and -5-.

Fig 7: Identifying Senors And Clamps

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-- Disconnect the connector from the Charge Air Pressure Sensor -G31- -arrow-.

-- Remove the bolts -1- and -4- and then remove the air guide pipe downward.

-- Disconnect the connectors -1, 2 and 3- underneath the intake manifold.

Fig 8: Connectors

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-- Remove the turbocharger, refer to TURBOCHARGER .

-- Remove the bolts -arrows-.

Fig 9: Cylinder Head Loosening Sequence

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-- Remove the cylinder head bolts in the sequence -1 to 10-.

NOTE:

Make sure all wires and cables are disconnected.

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

-- Remove the cylinder head.

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