Cylinder Head, Removing And Installing: Removing

WARNING: This page is about a different variant/trim than selected.

NOTE:

Before installing the cylinder head the engine support and the engine mount are temporarily re-installed because the eyes from the engine support bridge are secure on the cylinder head.

When installing, secure all cable ties back to same positions.

Close the open channels from the intake tube and exhaust tract with suitable plugs from the : VAS6122 .

Cover the opening of the transmission with a cleaning cloth, so that no coolant enters the clutch housing.

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the turbocharger air duct pipe/charge air cooler. Refer to TURBOCHARGER AIR DUCT PIPE/CHARGE AIR COOLER, REMOVING AND INSTALLING .

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

-- Remove the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

-- Reinstall the engine support and engine mount and tighten the bolts hand-tight.

-- Disengage the : 10-222A spindles.

-- Remove the front exhaust pipe with catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Remove the Oxygen Sensor 1 before Catalytic Converter -GX10-. Refer to Oxygen Sensor 1 before Catalytic Converter -GX10-, REMOVING AND INSTALLING .

-- Loosen the hose clamp -arrow- and remove the right charge air hose -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal the open lines and connections with clean plugs from the : VAS6122 .

-- Loosen the hose clamp -2-.

Fig 1: Disconnect Charge Air Pressure Sensor Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up the coolant hose -3-.

-- Remove the bolts -arrows-.

-- Disconnect the connector -1- from the Charge Air Pressure Sensor -G31- and remove the right air duct pipe.

-- Loosen the hose clamps -arrows- and remove the coolant hoses.

Fig 2: Identifying Clamps And Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pivot the coolant line -1- to the side.

-- Disconnect the connectors:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1 -

For the Oil Pressure Switch -F1-

2 -

For the Reduced Oil Pressure Switch -F378-

5 -

For the Piston Cooling Nozzle Control Valve -N522-

-- Remove the bolts -arrows- for the coolant pipe -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -1- and the nut -3- and then remove the bracket -2- for the intake manifold.

Fig 3: Identifying Bolt And Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors:

Fig 4: Disconnect Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

For the Throttle Valve Control Module -GX3-
For Intake Manifold Sensor -GX9-
For the Fuel Pressure Sensor -G247-

-- Remove the connector -4- from the bracket.

-- Free up the wiring harness and push it to the side.

-- Disconnect the connector -3- for Knock Sensor 1 -G61- from the bracket.

Fig 5: Knock Sensor Connector Locations

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors -2 and 4-.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2-.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the heat shield -2-.

-- Remove the bolt -1-. Only loosen the bolt -3-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the turbocharger bracket -2-.

-- Remove the nuts -arrows-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the turbocharger from the cylinder head and tie up toward the rear.

-- Remove the bolts -arrows-.

Fig 6: Cylinder Head Loosening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

Make sure all wires and cables are disconnected.

-- Remove the cylinder head and place it on a soft surface (foam).