Test sequence

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.

Remove intake manifold and cylinder head cover → Cylinder head cover, removing and installing ; Removing and installing cylinder head.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft over on vibration damper securing bolt in engine direction of rotation - arrow -. The Camshaft bar T10068 must engage in both shaft grooves.

Fig 2: Camshaft Bar T10068 Engaged In Both Shaft Grooves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If the camshaft bar will not fit:

Turn crankshaft one full turn further in engine direction of rotation.

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).

Check setting marks of camshaft timing adjusters with marks on control housing:

Fig 3: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Marks - A - and - B - on camshaft timing adjusters must align with notches - arrows - on control housing - C -.

Distance between tooth - 1 - and tooth - 2 - of camshaft timing adjuster must be exactly 16 rollers of camshaft roller chain.

NOTE:

Illustration shows a cover which has been removed.

If the marks do not align:

Adjust valve timing → Valve timing, adjusting .

If the marks align:

Install cylinder head cover and intake manifold → Cylinder head cover, removing and installing ; Removing and installing cylinder head.