Cylinder Head, Removing And Installing: Removing

• During installation, all cable ties must be installed at the same location.
• Always seal off any open channels of the intake and exhaust tract with suitable plugs, for example from the Engine Bung Set:VAS6122  .

-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

-- Remove the Throttle Valve Control Module -GX3-. Refer to Throttle Valve Control Module -GX3-, REMOVING AND INSTALLING .

-- Drain the coolant. Refer to DRAIN THE COOLANT .

-- Versions with catalytic converter and particulate filter: remove the bolt -arrow- on the bracket for the catalytic converter.

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-- Versions with catalytic converter without particulate filter: remove the bolt -3- on the bracket for the front muffler.

Fig 1: Threaded Connection - Front Muffler, Vehicle without Particulate Filter

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-- Place a cloth underneath to catch leaking engine oil.

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-- Remove the bolt -arrow- and then remove the oil return line.

-- Disconnect the connectors and free up the wires.

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1 -  For the Turbocharger Recirculation Valve -N249-

3 -  For Charge Air Pressure Control Module -GX34-

-- Press the release buttons on both sides and remove the crankcase ventilation hose -4-.

-- Remove the bolts -arrows- and remove the connection -2-.

-- Remove the bolts -arrows- and remove the heat shield -1-.

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-- Pry out the locking plates -arrows- and dispose.

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-- Remove the bolts -1 and 2- and also the oil supply line and the coolant line.

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-- Remove the nuts -arrows- and remove the turbocharger from the threaded pins.

-- Remove the right coolant pipe bolts -arrows-.

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-- Remove the connectors -2 and 3- from the bracket and disconnect.

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-- Disconnect the connectors -4 and 5-.

-- Remove the bolts -1- from the bracket.

-- Disconnect the connector -2- for the Manifold Absolute Pressure Sensor -G71-.

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-- Disconnect the connectors:

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1. For the Oil Pressure Switch -F22-
2. For the Reduced Oil Pressure Switch -F378-
3. For the Piston Cooling Nozzle Control Valve -N522-

-- Loosen the hose clamp -1- and remove the rear coolant hose.

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-- Disconnect the connector -2- for the Engine Coolant Temperature Sensor - G62-.

-- Remove the spark plugs with the Spark Plug Removal Tool:3122B  .

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-- Remove the bolts -arrows-.

Fig 2: Cylinder Head Loosening Sequence

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-- Remove the cylinder head bolts using the Socket - XZN 12:T40270  in sequence -1 through 10-.

-- Check if all hose and line connections are loosened.

-- Remove the cylinder head.

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

-- Seal the open channels of the intake and exhaust tract with clean cloths or with thoroughly cleaned plugs from the Engine Bung Set:VAS6122  .