Volkswagen Workshop Service and Repair Manuals

Removing cylinder head l  The engine must be no more than warm to touch.   Note t  All cable ties that are opened or cut through during removal must be secured in the same position on installation. t  If engine oil is contaminated, perform oil change → Booklet38. Carry out the following work: –  First check whether a coded radio unit is installed; in this case, request anti-theft coding. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27. –  Remove plenum chamber bulkhead → Rep. gr.50. –  Remove intake manifold → Chapter. –  Drain coolant → Chapter. –  Remove right wheel housing liner front part or front right wheel housing liner → Rep. gr.66. –  Remove front exhaust pipe with catalytic converter → Chapter.

–  Pull charge air hose -arrow- from charge air cooler.

–  Unscrew bolts -arrows- and remove charge air pipe. –  Pull off or disconnect all other electrical connections from turbocharger and lay to side.

–  Unscrew oil supply line and coolant supply line from turbocharger -arrows-.

–  Remove oil return line -arrows- from turbocharger.

–  Unscrew bolts -1- and -2- and remove support for turbocharger. –  Remove battery → Rep. gr.27.

–  Remove battery tray.

–  Pull off coolant hoses -1- and -2-. –  Pull off or disconnect all other electrical connections as necessary from cylinder head and lay to side.

–  Unscrew cable bracket and lay wiring harness to one side.

–  Unscrew coolant flange -arrows-. –  Remove poly V-belt → Chapter. –  Remove locking pin -T10060A- from tensioning device for poly V-belt. –  Remove toothed belt → Chapter. –  Remove cylinder head cover → Chapter.

–  Maintain sequence when loosening and tightening cylinder head bolts.   Note Check that all hose and line connections between engine, gearbox and body have been detached. –  Remove cylinder head.