Cylinder Head: Removing

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Before removing the cylinder head, extract the fuel with the hand vacuum pump and the draining container V.A.G 1390/1 TANDEM PUMP .

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

-- Remove engine cover.

One Piece Engine Cover

Fig 1: Identifying Removal Of One Piece Engine Cover

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Pull the one piece front engine cover -arrows A- upward with a quick jerk and then pull the lower mount -arrow B- forward.

Two Piece Engine Cover

Fig 2: Identifying Removal Of Two Piece Engine Cover

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On the two piece engine cover, first pull the outer cover upward with a quick jerk -arrows in the upper illustration-, then pull the inner engine cover upward with a quick jerk -arrows in lower illustration-.

-- Remove plenum chamber bulkhead Description and Operation .

-- Disconnect the connector -2- on the Mass Air Flow (MAF) sensor -G70-.

Fig 3: Identifying Ventilation Hose -1-, Electrical Harness Connector -2-, Spring-Type Clip -3-, Bolt -4- And Intake Manifold -5-

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-- Disconnect the ventilation hose -1- and disengage it from the bracket -arrow-.

-- Open the spring-type clip -3- using spring-type clip pliers VAS 5024A and disconnect the intake hose from the Mass Air Flow (MAF) sensor -G70-.

-- Disconnect the intake manifold -5- from the air guide.

-- Unfasten bolt -4- and remove air filter housing and mass air flow sensor.

-- Remove noise insulation Removal and Installation .

-- Drain the coolant COOLING SYSTEM, DRAINING AND FILLING .

-- For safety reasons, pull the connector -arrow- off the fuel delivery unit.

Fig 4: Identifying Fuel Delivery Unit Connector

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-- Disconnect the fuel supply and return lines, as well as the coolant line on the cylinder head.

-- Before removing the cylinder head, extract the fuel with the diesel extractor VAS 5226 or the hand vacuum pump and the breather reservoir V.A.G 1390/1 to the tandem pump TANDEM PUMP .

Fuel Filter Without the Retaining Plate

-- Release the clips and remove the fuel filter with the hoses still connected from the retaining plate -arrow-.

Fig 5: Identifying Fuel Filter Pulled Out Of Bracket

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Fuel Filter With the Retaining Plate

-- Loosen the bolt -1- one turn.

Fig 6: Identifying Bolt And Nut

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-- Remove the bolt -2- and the nut -3-.

-- Remove the fuel filter with the hoses still connected.

Continuation for All

-- Remove the front exhaust pipe FRONT EXHAUST PIPE .

-- Remove the turbocharger support and the oil return from the turbocharger.

-- Remove the oil supply line and lay the oil supply line off to the side OIL SUPPLY LINE .

NOTE:

From 06.05 a revised engine mount is being installed, which no longer requires that the engine mount be removed and that the engine be supported "Toothed Belt, Removing and Installing, Tensioning" TOOTHED BELT .

-- Remove toothed belt TOOTHED BELT .

-- Remove the toothed belt tensioning roller.

-- Remove hub for camshaft sprocket CAMSHAFT .

-- Remove the bolts for the rear toothed belt guard -2- and -4-.

Fig 7: Identifying Bolts For Rear Toothed Belt Guard & Camshaft Position (CMP) Sensor G40

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-- Remove the Camshaft Position (CMP) sensor -G40- -3-.

-- Remove the connecting pipe for exhaust gas recirculation.

-- Pull off/disconnect all remaining electrical wires required from cylinder head and set aside.

-- Disconnect all connections, coolant lines, vacuum hoses and intake hoses from the cylinder head.