Volkswagen Workshop Service and Repair Manuals

Removing   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  To avoid damage to lines/wiring, ensure sufficient clearance to all moving or hot components. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50. –  All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. –  Remove intake manifold → Chapter.

–  Pull off 2-pin connector from coolant temperature sender -G62--arrow-. –  Drain coolant → Chapter. –  Now, remove thermostat housing → Chapter.

–  Set crankshaft to TDC No. 1 cylinder marking -arrow- by turning crankshaft on the vibration damper securing bolt in direction of engine rotation. –  Remove cylinder head cover → Chapter.

–  Remove chain tensioner for camshaft timing chain -arrow-. –  Disconnect connectors from the following components of cover: t  Inlet camshaft control valve 1 -N205- t  Exhaust camshaft control valve 1 -N318- t  Hall sender -G40- t  Hall sender 2 -G163-   Note Before removing connectors, mark each connector and component to which it belongs. –  Move wiring harness clear.

–  Now unscrew camshaft cover -arrows-. –  First remove exhaust camshaft adjuster.   Note

Only counterhold at camshaft with 32 mm open-end spanner -arrow-. The camshaft bar -T10068 A- must not be fitted when camshaft adjuster is loosened or tightened. –  Now remove the camshaft adjuster together with the camshaft timing chain from the inlet camshaft. –  Lay camshaft timing chain aside.

–  Unbolt control housing from cylinder head -arrows-. –  Pull valve timing housing carefully off camshaft seals.

A - inlet camshaft –  First remove bearing caps 1 and 13. –  Remove bearing caps 3 and 11. –  Remove bearing cap 7. –  Loosen bearing caps 5 and 9 alternately and diagonally.

B - exhaust camshaft –  First remove bearing caps 2 and 14. –  Remove bearing caps 4 and 12. –  Remove bearing cap 8. –  Loosen bearing caps 6 and 10 alternately and diagonally. –  Carefully remove camshafts and lay aside on clean surface. –  Remove roller rocker fingers together with support elements and lay aside on a clean surface. –  Ensure that roller rocker fingers and support elements are not interchanged.