Camshafts, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE:

All cable ties which are opened or cut open during disassembly, must be replaced in the same position during installation.

Remove engine cover.
Check whether a coded radio is installed. If so, obtain anti-theft coding.
With ignition switched off disconnect battery Ground strap.
Remove intake manifold → Cylinder head cover, removing and installing , Removing and installing cylinder head cover.

Fig 1: Locating Engine Coolant Temperature Sensor G62

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 4-pin connector - arrow - from Engine Coolant Temperature (ECT) sensor G62 with Engine Coolant Temperature (ECT) sensor G2.
Drain coolant → Cooling system, draining and filling .
Remove coolant thermostat housing → Components of cooling system, engine side , Parts of cooling system, engine side.

Fig 2: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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Set crankshaft to TDC No. 1 Cyl. marks - arrow - by turning crankshaft on vibration damper securing bolt in engine direction of rotation.
Remove cylinder head cover → Cylinder head cover, removing and installing .

Fig 3: Locating Camshaft Roller Chain Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove camshaft roller chain tensioner - arrow -.

Fig 4: Identifying CMP Sensor G40, CMP Sensor 2 G163 And Connectors

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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 N318 - 4 -.

NOTE:

Mark connector and component before disconnecting.

Release and free wiring harness.
Remove camshaft cover → Cover, removing and installing .

Fig 5: Identifying Markings On Roller Chains

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Mark roller chains before removing (e.g. with paint, - arrow - pointing in direction of rotation).

NOTE:

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

First remove exhaust camshaft timing adjuster.
Remove camshaft timing adjuster together with camshaft roller chain from intake camshaft.

Fig 6: Camshaft Counter Support Area

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NOTE:

Counter-support on camshaft with a 32 mm open end wrench - arrow -. Camshaft bar T10068 must not be installed when loosening or tightening the camshaft timing adjuster.

Place camshaft roller chain to side.

Fig 7: Locating Control Housing-To-Cylinder Head Bolts

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Remove control housing from cylinder head - arrows -.
Pull control housing carefully of camshaft seals.

A - Intake camshaft

Fig 8: Identifying Intake And Exhaust Camshafts

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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, and remove.

B - Exhaust camshaft

Fig 9: Identifying Intake And Exhaust Camshafts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 place on a clean surface.
Remove roller rocker finger together with support elements and place on a clean surface.

NOTE:

Ensure the roller rocker fingers and the support elements are not interchanged.