Volkswagen Golf / Golf GTI / Jetta. Manual — part 33

15-27

- Remove intake manifold

Page 15-16

,

Removing and installing cylinder head cover.

- Disconnect 4-pin connector (arrow) from Engine

Coolant Temperature (ECT) sensor -G62
Engine Coolant Temperature sensor -G2

- Drain coolant

Page 19-15

.

- Remove coolant thermostat housing

Page 19

6

, Parts of cooling system, engine side.

- Turn crankshaft on vibration damper securing

bolt in engine direction of rotation to TDC cyl. 1
(arrow).

- Remove cylinder head cover

Page 15-

Cylinder head, servicing

15-28

- Remove camshaft roller chain

tensioner (arrow).

Note:

Mark connector and component
before disconnecting.

- Disconnect connections from

following components on cover:

Camshaft Position (CMP)

sensor -G40- -1-,

Camshaft Position (CMP)

sensor 2 -G163- -2-,

Valve -1- for camshaft

adjustment -N205- -3-,

Camshaft adjustment valve 1

(exhaust) -N318- -4-.

- Release and free wiring harness.

Cylinder head, servicing

15-29

- Remove camshaft cover

Page 15-11

;

Removing and installing camshaft.

Note:

Do not mark chain with a punched mark, notch or
similar!

- Mark roller chains before removing (e.g. with

paint, arrow pointing in direction of rotation).

- Separate front exhaust pipe from exhaust

manifold

Page 26-1

, Removing and installing

parts of exhaust system.

- Check timing settings:

Note:

This condition only occurs at every 2nd TDC
position.

When correctly positioned at TDC cyl. 1, a

groove (arrow) can be seen in intermediate shaft
chain sprockets

Cylinder head, servicing

15-30

If the notch cannot be seen:

- Turn crankshaft one full turn further in engine

direction of rotation.

Note:

When the crankshaft is turned, the tensioning rail
must be pressed against the camshaft roller
chain by hand instead of with the chain
tensioner.

Note:

If the camshaft bar cannot be installed, turn the
crankshaft in engine direction of rotation until
approx. 5 mm past the TDC setting for No. 1 cyl.
(dependent on drive chain tolerances).

The camshaft bar T10068 must engage in both

shaft grooves.

Cylinder head, servicing