Cylinder Head: Removing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 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 VAS 6122.

-- 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.