Cylinder head cover, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 Volkswagen Jetta, 2002 Volkswagen GTI, 2001 Volkswagen Jetta, 2001 Volkswagen GTI, and 2000 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The ground strap must be disconnected for this procedure. Check to see if a coded radio is installed. If that is the case, you must first obtain the anti-theft code.

With ignition off, disconnect battery ground strap.
During installation you must reinstall at same locations all tie straps that were loosened or cut during removal.
Remove spark plug connector with assembly tool T10029 and unclip ignition lines: Refer to 28 IGNITION/GLOW PLUG SYSTEM
Remove engine cover. Refer to 24 MULTIPORT FUEL INJECTION (MFI)

Disconnect connector from positive crankcase ventilation PCV heating element N79.
Remove inlet hose between Mass Air Flow (MAF) Sensor G70 and Throttle valve control module J338. Refer to 24 MULTIPORT FUEL INJECTION (MFI)

Fig 1: Connector Disconnected From Throttle Valve Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 - from throttle valve control module - 2 -.
Unscrew ground connection at Throttle valve control module J338.
Open and close balancing reservoir sealing cover to allow pressure to escape from cooling system.

Fig 2: Coolant Hoses At Throttle Valve Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant hoses - 1 - and - 2 - from throttle valve control module and plug hose ends.
Unclip fuel lines at cylinder head cover.

Fig 3: Vacuum Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum connectors - arrows -.
Unclip secondary air pump inlet line and all other lines from brackets at top half of intake manifold.
Unscrew dipstick duct at top half of intake manifold.
Remove two intake manifold support screws.

Remove vacuum hose at intake manifold switching vacuum actuator.

Fig 4: Identifying Supply Line And Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect flow hose - 1 - (with white marking) and return hose - 2 - (with blue marking) and catch leaking fuel with a clean rag.

NOTE:

In order to do this, press the tabs at the hose couplings together.

CAUTION: The fuel system is pressurized. Before opening the system, plane a clean rag around the connection. Then reduce pressure by carefully and slowly loosening the connection.

Plug lines so that dirt cannot enter fuel system.
Remove middle, left and right damping pans: Refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW or NOISE INSULATION (DIESEL ENGINES), ASSEMBLY OVERVIEW
Put lock carrier into service position: Refer to LOCK CARRIER SERVICE POSITION

Vehicles with air conditioning

Remove V-ribbed drive belt, refer to Ribbed V-belt, removing and installing .
Remove A/C compressor: Refer to A/C COMPRESSOR AND BRACKET
Unscrew refrigerant line retainer clamp(s).

CAUTION: Do not open the A/C system refrigerant circuit.

NOTE:

Opening the refrigerant circuit can be done only in shops which have available properly trained personnel as well as all of the necessary tools and equipment.
To avoid damage to the condenser, coolant lines and hoses, make sure that the lines and hoses are not being overstretched, crimped or bent.

Continued for all vehicles

Remove combination valve, refer to Combination valve, removing and installing .
Unscrew upper intake manifold from lower intake manifold.
Remove upper intake manifold and place it on a suitable surface so that vacuum actuator will not be damaged.

NOTE:

Plug the intake ducts in the lower intake manifold or cylinder head with a clean rag.

Remove cylinder head cover.