Cylinder Head: Removing

WARNING: This page is about a different car, the 2014 Volkswagen Beetle and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Coat all contact surfaces between the support elements, the roller rocker levers and the lubricating surfaces on the camshaft with oil before installing the "replacement cylinder head".

The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.

Replace the cylinder head bolts.

It is necessary to replace all the engine coolant when the cylinder head or cylinder head gasket are replaced.

WARNING: Hot steam may escape when opening the reservoir.

Wear protective eyewear and protective clothing to prevent eye injury and scalding.
Cover the cap with a cloth and open very carefully.

-- Follow repair instructions. Refer to GENERAL INFORMATION .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Remove the air filter (engine cover). Refer to AIR FILTER HOUSING .

-- Remove the intake hose -4- between the Throttle Valve Control Module -J338- and air filter. To do this, disconnect air hose -1-, if present, and air hose -2- (compress securing ring) and remove spring clamp -3-.

Fig 1: Identifying Air Hoses And Are Fitted Securely

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the battery and the battery tray. Refer to REMOVAL AND INSTALLATION .

-- Remove the intake manifold. Refer to INTAKE MANIFOLD .

-- Attach the transport strap to the cylinder head again to hold the cylinder head when removing it.

-- Remove the timing chain guard. Refer to TIMING CHAIN COVER .

-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Lock the camshafts and remove the camshaft chain sprockets. Refer to VALVE TIMING, ADJUSTING .

-- Hold the timing chain -A- as shown so that it can be routed below the pipe connection -arrow-.

Fig 2: Holding Timing Chain To Be Able To Lay It Under Pipe Connection

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the four nuts -2- and the bolts -3-.

Fig 3: Identifying Nuts, Bolts & Front Exhaust Pipe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front exhaust pipe -1- from the exhaust manifold and tie it to the side. Refer to CATALYTIC CONVERTER .

CAUTION:

Do not bend the decoupling element more than 10°.
Do not stretch the decoupling element.
Do not damage the wire mesh on the decoupling element.

-- Disconnect the connector for the Heated Oxygen Sensor -G39- at the bulkhead.

-- Unscrew cable bracket bolt -arrows- and remove cable bracket -3- at air injection valve or sealing cap (engines without secondary air injection system).

Fig 4: Disconnecting Harness Connectors And & Removing Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the cylinder head bolts in specified sequence.

Fig 5: Identifying Cylinder Head Bolts Removed In Sequence Specified

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the bolt -2- was not able to be pulled out using a magnet, loosen bolts of Camshaft Clamp T40070 one rotation, slide Camshaft Clamp T40070 toward front at right (seen in direction of travel) and tighten bolts again.

A second technician will be needed to remove and install the cylinder head.

-- Carefully remove cylinder head.