Cylinder head cover, removing and installing: Removing
WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 1999 Volkswagen Jetta, 1999 Volkswagen GTI, 1998 Volkswagen Jetta, 1998 Volkswagen GTI, and 1997 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect Spark Plug connectors with ignition cables:
See MOTRONIC IGNITION SYSTEM, COMPONENTS
Removing ignition cable guides -1- and -2-.
- Remove cover -3- above upper intake manifold.
- Disconnect Positive Crankcase Ventilation (PCV) Breather Valve from cylinder head cover.
- Disconnect hose (from PCV Breather to Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from upper intake manifold.
WARNING:
On vehicles without Positive Crankcase Ventilation (PCV) Breather Valve, make especially sure that the EVAP Canister breather hose is installed correctly (danger of fire), see CYLINDER HEAD, INSTALLING , Fitting Position Of Activated Charcoal Filter Breather Hose On Upper Intake Manifold and Fitting position of the crankcase breather hose on cylinder head cover .
- Remove Intake Air duct from throttle valve housing.
- Separate connectors from Throttle Position (TP) Sensor (G69), heater element, Idle Air Control (IAC) Valve (N71) and Intake Air Temperature (IAT) Sensor (G72).
- Detach Accelerator Pedal cable from throttle valve housing and support bracket (do not remove locating clip).
- Disconnect coolant hose from throttle valve housing and seal (first release pressure from cooling system).
WARNING:
First slowly release pressure from cooling system.
- Disconnect vacuum hoses from Fuel Pressure Regulator and vacuum brake booster.
- Unclip fuel lines from cylinder head cover.
- Detach dipstick guide tube from lower intake manifold.
- Remove upper intake manifold (with throttle valve housing).
NOTE:
Seal intake ports with clean cloth.
- Remove cylinder head cover.