[D2Beetle]

Saturdays instructional pictorial...

Step Eight: [CCH DIY 015] Removing the fuel injector wiring harness #2, 2A, 2B and 2C. Before you can remove the fuel injector wiring harness you will have to disconnect seven sensors which are part of the same wiring harness (#1) which goes under the intake manifold to four separate sensors.

Step Nine: [CCH DIY 016 and 017] First remove the intake manifold tube #4 and vacuum hose #2 then disconnect related air intake sensors #1 and #3. My first surprise is noted in pic 017 by the ? box. What it indicated I did not know at the time, I just annotated it and kept going.

Step Ten: [CCH DIY 018] Disconnect cam timing sensor #5.

Step Eleven: [CCH DIY 020] Disconnect the two crank sensors #7 and #8. I do not know the names of sensors #6 and #9, but disconnect them anyway. Ensure that you disconnect any positional/routing clamps and try not to break them as wiring is routed to keep it protected and away from heated surfaces. Now you have to pull/push/twist the #1 wiring harness through the slot between intakes one and two; you will have to do it one sensor connector at a time as there is just enough space, so do it gently as you do not want to crack any of the sensor connectors or pull out the wires.

Step Twelve: [CCH DIY 023, 024 and 025] Remove "this thing" that is on top of the valve cover. It has two sensor connectors #6 and #8. BE REALLY CAREFUL HERE AS THE VACUUM HOSE CONNECTIONS ARE PLASTIC AND BREAK EASILY. Disconnect the vacuum hoses #1, #7 and #9. Remove mounting bolts #2, #3, #4 and #5 and the entire assembly can be removed. The cloth braiding on the vacuum hose will probably fray and come off and there is nothing that you can do about. I will be replacing all vacuum hoses during re-installation.

Step Thirteen: [CCH DIY 031 & 032] Remove the coil packs; disconnect the wiring harness connections #3 first. I always have a problem pushing the "connector release" to get any wiring harness off, so I made my own tool to do it. I used a piece of a cotter pin which are strong but flexible and if I put too much force on it the cotter pin bends instead of breaking the plastic. This tool works on any size connector. Put the "L" shaped tool in the connector as shown in #3 and with a little twist of the wrist the connector release will "release". Use your other hand to slide the connector off of the coil pack. The coil pack wiring harness is held down by two plastic stoppers #4, simply use a flat head screw driver to pry them up. Remove bolts #1 and #2 and pull out the coil pack; they might be a little difficult to get out if it has been long since their last removal. Lastly #5 is a support bolt for another vacuum hose, remove it.

Step Fourteen: [CCH DIY 036 & 037] Shows what it looks like when all of the items noted above are removed.