Cylinder Head: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: During installation, all heat insulation sleeves must be installed at the same location.

-- Remove the engine cover, refer to ENGINE COVER .

-- Remove the front upper coolant pipes, refer to FRONT UPPER COOLANT PIPE .

-- Remove the rear coolant pipe, refer to REAR COOLANT PIPE .

-- Remove the left coolant pipes, refer to LEFT COOLANT PIPES .

-- Remove the front exhaust pipe, refer to FRONT EXHAUST PIPE .

-- Remove the upper toothed belt guard, refer to Removing .

-- Remove the toothed belt from the camshaft, refer to Removing .

-- Remove the cylinder head cover, refer to Removing .

-- Open the heat shield boot -1-.

Fig 1: Identifying Heat Shield Boot And Connectors

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-- Disconnect the connectors -3, 5 and 6- and free up the wiring harness.

-- Remove the bolt -2-.

-- Disconnect the connector -4-.

-- Lay the bracket with the differential pressure sensors to the rear.

-- If equipped remove the vacuum hose -arrow-.

Fig 2: Identifying Vacuum Hose

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-- Remove the hose -1- for the crankcase ventilation on the air guide hose.

Fig 3: Identifying Release Buttons

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-- To do this press the release button.

CAUTION: Depending on the vehicle equipment level and market-specific crankcase ventilation hose may be used, which cannot be removed from the cylinder head cover without being destroyed. For these version the crankcase ventilation hose can only be separated at the air guide hose connection.

-- Release the connector from the air guide hose and remove.

-- Unclip the wires on the intake tube.

-- Free up the vacuum hoses -arrows- on the air guide pipe.

-- Remove bolt -2- and tilt the air guide hose with the intake tube backward and remove from the turbocharger.

-- Remove the bolt -arrow-.

Fig 4: Identifying Turbocharger Warm Air Connection

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-- Unclip and remove the pre-heater pipe -1- from the bracket.

-- Remove the bolts -arrows- and the resonator -1-.

Fig 5: Identifying Reasonator With Bolts

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NOTE: Use the Pry Lever 80-200 for removing the spiral clips in the following procedure.

Fig 6: Free Electrical Wiring Up To Generator Using 80-200

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-- Free up the wires from the connectors -1- to -3-.

Fig 7: Disconnect The Black

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-- Free up the wiring harness from the cylinder head cover.

-- Disconnect and remove the connector -1- (attached behind the bracket).

Fig 8: Disconnect Connectors

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-- Unclip the connector -1-.

-- Guide the lines out of the brackets -2- on the plenum chamber bulkhead and turbocharger.

-- Unlock and disconnect the connector -2- from the Wastegate Bypass Regulator Valve -N75- -1-.

Fig 9: Identifying Connector And Wastegate Bypass Regulator Valve

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-- Remove the nuts -arrows-.

-- Move the Wastegate Bypass Regulator Valve -N75- -1- with the vacuum lines aside.

-- Remove the NOx Sensor -G295- control module and place on the engine with the lines, refer to NOx Sensor -G295- .

-- Push the heat shield boot aside, and disconnect the connector -5-.

Fig 10: Identifying Air Guide Hose

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-- Loosen the clamp -3- and remove the air guide hose.

-- Loosen the hose clamp -4- and remove the coolant hose.

-- Remove bolt -1- and loosen bolt -2-.

-- Loosen the bolt -1- and remove the screw-type clamp.

Fig 11: Identifying Bolts

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-- Loosen the double bolt -2- and place the coolant pipe slightly to the rear.

-- Remove the bolts -arrows-, and push the emissions control module rearward.

-- Remove the bolt -2- and union nut -4-.

Fig 12: Identifying Bolts

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-- Remove bolts -3 and 5- and the oil return pipe.

-- Remove the bolt -2-, and only loosen the bolts -1, 3, and 4-.

Fig 13: Emissions Control Module Bracket - Tightening Specifications and Tightening Sequence

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-- Disconnect and remove the connectors -1- and -3-.

Fig 14: Identifying Hose Clamp

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-- Loosen the hose clamp -2-.

-- Disconnect and free up the connectors.

Fig 15: Identifying Connectors

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1 -

for Charge Air Temperature Sensor after Charge Air Cooler - G811-

3 -

for Charge Air Pressure Sensor -G31-

4 -

for Intake Air Temperature Sensor -G42-

5 -

for the Throttle Valve Control Module - J338-

-- Remove the bolts -2, and 7-, and remove the coolant hose -6-.

-- Remove the bolt -1- for the oil dipstick guide tube.

Fig 16: Identifying Oil Dipstick Guide Tube Bolt

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-- Remove the bolts -2, 3- for the intake manifold bracket.

-- Remove the Throttle Valve Control Module -J338-, refer to Throttle Valve Control Module -J338- .

-- Remove the camshaft housing, refer to Removing .

-- Disconnect the connector -3- and remove from the cover -2-.

Fig 17: Identifying Cover Bolt

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-- Remove bolt -1- and remove the cover.

-- Open the retainer -arrow- and remove the vacuum hose -1-.

Fig 18: Identifying Retainer

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-- Remove the vacuum hose -2-.

-- Remove the bolt -3-.

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

Fig 19: Identifying Hose Clamp

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

-- Remove the vacuum hose -3-.

-- Disconnect the connector for the glow plug.

Fig 20: Identifying Pliers 3314 Positioned With Groove

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-- Move the electrical wiring harness to the side.

-- Loosen the cylinder head bolts in the sequence -1 to 10-.

Fig 21: Identifying Cylinder Head Bolts

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NOTE: A second technician is needed to remove the cylinder head.

-- Move the cylinder head from the rear toothed belt guard toward the left and remove the tensioning roller at the same time.

-- Be careful not to damage the turbocharger oil return line.

-- Lay the cylinder head down being careful not to bend the oil return line. Place a piece of wood under the exhaust manifold if necessary.

CAUTION: Danger of damaging the glow plugs when removing the cylinder head.

Do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface.