Cylinder head, removing and installing: Removing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

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 (e.g. for fuel, hydraulic, EVAP system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

Check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
Disconnect battery Ground (GND) strap with the ignition switched off.

NOTE:

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

Unbolt front exhaust pipe from exhaust manifold, refer to Exhaust system components, removing and installing .

NOTE:

Before disconnecting harness connectors, mark allocation to component.

Fig 1: Identifying CMP Sensor G40, CMP Sensor 2 G163 And Connectors

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate the connections from camshaft position (CMP) sensor G40 - 1 - and camshaft position (CMP) sensor 2 G163 - 2 -.
Pull off the connectors - 3 - and - 4 -.
Remove intake manifold, refer to Cylinder head cover, removing and installing .

CAUTION: Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Fig 2: Identifying Supply Line & Fuel Return Line

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off fuel supply line - 1 - (with white marking) and fuel return line - 2 - (with blue marking) at fuel rail, and catch any released fuel with a shop rag.
Seal lines so that the fuel system is not contaminated by dirt etc.
Unclip fuel lines at cylinder head cover.

Fig 3: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft at vibration damper securing bolt in engine direction of rotation to TDC cyl. 1 - arrow -.

Fig 4: Locating Engine Coolant Temperature Sensor G62

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 2-pin connector from Engine Coolant Temperature (ECT) Sensor G62 - arrow -.
Drain coolant, refer to Cooling system, draining and filling under Cooling system, draining and filling .
Remove thermostat housing, refer to Cooling system components (on engine), assembly overview .
Remove cylinder head cover, refer to Cylinder head cover, removing and installing .

Fig 5: Locating Camshaft Roller Chain Tensioner

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove camshaft roller chain tensioner - arrow -.

Fig 6: Identifying Cover Bolts

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - from cover and remove it.

NOTE:

Do not mark chain with a center punch or similar means!

Fig 7: Identifying Markings On Roller Chains

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation).

Fig 8: Locating Counter-Hold Area On Camshaft

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Counter-hold only with 32 mm open end wrench on camshaft - arrow -. Camshaft bar T10068 A must not be installed when camshaft adjuster is loosened or tightened.

Remove exhaust camshaft adjuster.
Remove camshaft adjuster with camshaft roller chain from intake camshaft.

Fig 9: Locating Guide Rail & Bolts

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - for guide rail - 1 - and remove guide rail.
Place camshaft roller chain aside.

Fig 10: Socket Head Bolts Removal Sequence

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen socket head bolts in the given sequence from outside to inside and then remove completely.

Fig 11: Identifying Lifting Tackle 3033 & VAS 6100

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hook in lifting tackle 3033 as follows and carefully lift cylinder head with workshop crane VAS 6100. Vibration damper side: - Position 3 - and flywheel side: - Position 11 -

NOTE:

With 1 to 12 marked positions, point the lifting tackle toward the flywheel side.
The threaded spindles are adjusted to length as required.

Carefully lift cylinder head off.
Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
Prevent dirt and emery cloth particles from getting into the coolant.
Carefully clean cylinder head and cylinder block sealing surfaces. This ensures that no scoring or scratches are formed (when using abrasive paper the grade must not be less than 100).