Cylinder head cover, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE:

All cable ties which are opened or cut open during disassembly, must be replaced in the same position during installation.

Remove engine cover.
Check whether a coded radio is installed. If so, obtain anti-theft coding.
With ignition switched off disconnect battery Ground strap.

Fig 1: Identifying Ignition Coils

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connectors from ignition coils 1...6.

NOTE:

Mark connector and component before disconnecting.

Unclip ignition coils wiring harness from wiring guide.
Remove ignition coils with final output stage for cylinders 1...6 using puller T10095.
Pull off crankcase breather connecting hose between cylinder head cover and intake hose on cylinder head cover.
Remove intake hose between Mass Air Flow (MAF) sensor and throttle valve control module: → 24 MULTIPORT FUEL INJECTION (MFI)

NOTE:

Press buttons on hose couplings to do so.

Fig 2: Throttle Valve Control Module J338

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 6-pin connector from throttle valve control module - arrow -.
Open and close expansion tank cap to release pressure in cooling system.
Pull coolant hoses off throttle valve control module and seal hose ends.

Fig 3: Identifying Supply Line & Fuel Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull fuel supply hose - 1 - (with white marking) and fuel return hose - 2 - (with blue marking) off fuel rail and collect fuel that may leak out with a cloth.

CAUTION: Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

Seal lines to avoid contamination of fuel system.
Observe rules for cleanliness → Rules for cleanliness .

Fig 4: Retaining Frame On Cylinder Head For Fuel Lines And Wiring Harness

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove retaining frame on cylinder head for fuel lines and wiring harness - arrows -.

Fig 5: Intake Manifold Vacuum Hose Outlets

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Disconnect vacuum hoses - arrows - from intake manifold.

NOTE:

Press buttons on hose couplings to do so.

Remove rearmost bolt - 1 - for intake manifold support.
Unclip pressure hose (between combi-valve and secondary air pump motor) and all other lines from retainers on intake manifold and cylinder head cover.
Remove guide on cover for coolant hoses and wiring harness, -.
Remove Ground connection on support of combi-valve, -.

Disconnect vacuum hose from variable intake manifold change-over vacuum actuator.
Remove two lateral intake manifold support bolts.
Remove center, left and right insulation trays: → 50 BODY, FRONT
Disconnect connectors from thermal switch and coolant fan.

Removing front bumper: → 63 BUMPER
Bring lock carrier into service position: → 50 BODY, FRONT
Unscrew dipstick guide tube from intake manifold.
Remove intake manifold securing bolts and remove intake manifold together with throttle valve control module.

Remove intake manifold and place on a suitable surface so that vacuum actuator is not damaged.

NOTE:

Seal the intake ports in the intake manifold or in the cylinder head with a clean cloth.

Remove cylinder head cover.