Volkswagen Workshop Service and Repair Manuals

Removing   Note Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. –  With the ignition switched off, disconnect battery earth strap. –  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.

–  Unplug 3-pin connector from Hall sender -1-; sender remains installed. –  Unplug 5-pin connector from ignition transformer -2-. –  Remove ignition transformer → Chapter.

–  Unplug 4-pin connector from coolant temperature sender -G62- with coolant temperature gauge sender -G2--arrow-. –  Drain coolant → Chapter. –  Then remove thermostat housing → Chapter.

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

–  Clean drive chain and camshaft sprockets and mark running direction and installation position -arrows- with felt pen.   Note t  Do not mark chain by way of centre punch, notch or the like. t  Distance between coloured marks is 20 rollers on drive chain. –  Now unscrew camshaft cover.

–  Secure camshaft adjuster using chain tensioner retainer -T10067-.   Note Camshaft adjuster can be damaged if chain tensioner is tightened too far.

–  Remove camshaft adjuster -arrows-. –  Loosen camshaft timing chain sprocket together with drive chain sprocket at exhaust camshaft, while holding camshaft with 32 mm open-end spanner.   Note

Only counterhold camshaft with 32 mm open-end spanner -arrow-. The camshaft bar -T10068 A- must not be fitted when sprockets are being loosened or tightened. –  Remove sprocket together with camshaft roller chain from exhaust camshaft. –  Loosen inlet camshaft sprocket.   Note

Only counterhold camshaft with 32 mm open-end spanner -arrow-. The camshaft bar -T10068 A- must not be fitted when sprockets are being loosened or tightened. –  Remove sender wheel for Hall sender -G40- from inlet camshaft. –  Remove sprockets with drive chain from camshafts.

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.