Cylinder Head: Removing

WARNING: This page is about a different car, the 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.

-- Remove the engine cover. Refer to ENGINE COVER .

NOTE:

To perform work sequence, the Ground cable must be disconnected from battery. Check if a coded radio is installed. If so, obtain anti-theft coding beforehand.

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

Fig 1: Identifying Battery Tray And Bolts

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-- Remove the bolts -arrows-.

CAUTION:

Danger of causing damage to other electronic components when disconnecting the battery.

Complete the steps for disconnecting the Battery.

-- Remove the air filter housing with the mass air flow sensor and connecting pipe AIR FILTER HOUSING .

-- Disconnect the connector from the crankcase ventilation hose -1-.

Fig 2: Identifying Release Buttons

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

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

-- Remove the heat insulation sleeve.

Fig 3: Charge Pressure Actuator Position Sensor -G581 Connector

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-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

Fig 4: Identifying Turbocharger Vacuum Diaphragm

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-- Disconnect the connector -1- from the Charge Pressure Actuator Position Sensor -G581-.

-- Remove the vacuum line -1- from the brake booster -2-.

Fig 5: Identifying Vacuum Hose

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-- Remove the vacuum line -2- from the vacuum pump -1-.

Fig 6: Identifying Brake Booster Vacuum Pump (Diesel)

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-- Remove the vacuum hose -A- from the cylinder head cover.

Fig 7: Identifying Fuel Pressure Sensor Connector And Vacuum Hose

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

Fig 8: Identifying Connector And Wastegate Bypass Regulator Valve

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-- Remove the nut -arrows- from the Wastegate Bypass Regulator Valve -N75- -1-.

-- Move the vacuum line, the vacuum hoses and the Wastegate Bypass Regulator Valve -N75- to the side.

-- Disconnect the connectors -arrow A- and free up the wires.

Fig 9: Disconnect The Connector From The EGR Temperature Sensor

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

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

-- Remove the toothed belt. Refer to TOOTHED BELT .

-- Remove the camshaft sprocket and hub. Refer to CAMSHAFT .

-- Remove the Heated Oxygen Sensor - G39- and the Oxygen Sensor Heater - Z19-. Refer to Heated Oxygen Sensor -G39- .

-- Remove the exhaust gas temperature sensor - G495-. Refer to Exhaust Gas Temperature Sensor 3 -G495- .

-- Remove the exhaust gas temperature sensor -G648-. Refer to Exhaust Gas Temperature Sensor 4 -G648- .

Vehicles with a DSG transmission

Fig 10: Identifying Hose Clamps

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-- Loosen the hose clamps -arrows- and remove the coolant hoses from the transmission fluid cooler.

For all vehicles

-- Remove the bolts -2, 5 and 7-.

Fig 11: Identifying Bolts

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-- Unclip the wires and hoses with the Pry Lever 80 - 200 from the air guide pipe -1-.

-- Loosen the hose clamp -2- and remove the air guide pipe -1-.

-- Remove the engine lifting eye on the cylinder head :Engine Lifting Eye.

-- Remove the bolts -arrows-.

Fig 12: Identifying Pulsation Damper, Removal

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-- Remove the pulsation damper -2-.

-- Disconnect the connector -4- from the Engine Coolant Temperature Sensor -G62-.

Fig 13: Identifying Clamps

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-- Remove the bolts and then remove the connection from the cylinder head.

-- Disconnect the connector -1- from the Oil Pressure Switch -F1-.

Fig 14: Identifying Connector

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-- Disconnect the connector -2- from the EGR cooler.

Fig 15: Identifying EGR Cooler With Bolts

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-- Free up the wires near the cylinder head.

-- Loosen the clamp -1- for the connection between the turbocharger and the particulate filter and remove it.

Fig 16: Identifying Turbocharger/Particulate Filter Clamp

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NOTE:

The figure shows the clamp bolt -1- from underneath. This can also be installed from above in some cases.

-- Remove the bolt -1- on the upper particulate filter bracket.

Fig 17: Identifying Bolt

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-- Remove the nut -arrow- and then remove the bracket -1- on the upper cylinder head.

Fig 18: Identifying Nut And Bracket

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-- Remove the bolts -arrows-.

Fig 19: Identifying Bolts

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-- Free up the wires on the turbocharger.

-- Disconnect the connectors -1- from the EGR Vacuum Regulator Solenoid Valve -N18-.

Fig 20: Identifying Connectors

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-- Disconnect the connectors -3- from the Throttle Valve Control Module -J338-.

-- Remove the bolt -1- from the dipstick connection.

Fig 21: Identifying Dipstick Tube

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-- Open and remove the clamp -1-.

Fig 22: Identifying Clamp And Bolts

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-- Remove the bolts -2- and the connecting pipe.

-- Disconnect the connector -1- from the Camshaft Position Sensor -G40-.

Fig 23: Identifying Charge Air Pipe

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-- Unclip the connector on the coolant pipe.

-- Loosen the clamps -1- and -2- and remove the coolant hoses from the connections.

Fig 24: Identifying Clamps

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-- Loosen the bolts -1- and remove the heat shield from the right driveshaft.

Fig 25: Locating Heat Insulation Sleeve Bolts

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-- Loosen the nuts -1- and -2- on the particulate filter bracket.

Fig 26: Identifying Particulate Filter Mount And Nuts

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-- Remove the bolts -1- and -3-.

Fig 27: Identifying Bolts

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-- Remove the banjo bolts -4- and -5-.

-- Loosen the bolt and remove the oil supply line -2- from the turbocharger.

-- Remove the rear toothed belt guard bolt -arrow-, refer to :Bolt.

Fig 28: Identifying Nut To Toothed Belt Tension

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-- Remove the toothed belt tensioning roller nut, refer to :Bolt.

-- Remove the cylinder head bolt.

Fig 29: Cylinder Head Bolts Loosening Sequence

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Follow sequence -1- to -10- when loosening cylinder head bolts.

NOTE:

A second technician is needed when removing the cylinder head.

The toothed belt tensioning roller is pulled off the stud bolt when lifting the cylinder head out.

Free up and remove the wires for the Camshaft Position Sensor -G40- when removing the cylinder head. Refer to :Camshaft Position Sensor -G40-.

-- First lift the cylinder head on the transmission side and remove it from out of the toothed belt guard.

-- Be careful not to let the toothed belt tensioning roller fall.

-- Carefully lay the cylinder head down, on a piece of wood if necessary.