Volkswagen Cars 2000-05

Camshaft (Cylinder Head) Cover

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Removal & Installation



1.8L Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the valve cover trim, ignition coils and wiring.
  4.  
  5. Remove the valve cover fasteners.
  6.  
  7. Remove the valve cover gasket. Clean and prep the surface of the valve cover.
  8.  
  9. Clean the gasket mating surface of the cylinder head and spark plug chambers.
  10.  

To install:

  1. Apply a small bead of sealant to the front and rear corners where the camshaft journal cap and hydraulic chain tensioner meet the cylinder head.
  2.  
  3. Install a new spark plug chamber gasket and valve cover gasket, then the valve cover.
  4.  


NOTE
Always check to ensure that the valve cover gasket is properly seated on the head.

  1. Tighten the valve cover fasteners evenly using a crisscross pattern from the inside out to 88 inch lbs. (10 Nm).
  2.  
  3. The remainder of the installation is the reverse of removal.
  4.  

2.8L 5v V6 Engines
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the valve cover trim.
  4.  
  5. Label and remove the ignition wires.
  6.  
  7. Remove the valve cover fasteners.
  8.  
  9. Remove the valve cover gasket. Clean and prep the surface of the valve cover.
  10.  
  11. Clean the gasket mating surface of the cylinder head and spark plug chambers.
  12.  

To install:

  1. Apply a small bead of sealant to the front and rear corners where the camshaft journal cap and hydraulic chain tensioner meet the cylinder head.
  2.  
  3. Install a new spark plug chamber gasket and valve cover gasket, then the valve cover.
  4.  


NOTE
Always check to ensure that the valve cover gasket is properly seated on the head.

  1. Tighten the valve cover fasteners evenly using a crisscross pattern from the inside out to 88 inch lbs. (10 Nm).
  2.  
  3. The remainder of the installation is the reverse of removal.
  4.  



Click image to see an enlarged view

Fig. Apply a suitable sealant to the corners of the gasket surface-to-outer camshaft journals-2.6L 5V Engine shown

2.8L V6 Engines
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the valve cover trim.
  4.  
  5. Remove the valve cover fasteners.
  6.  
  7. Remove the valve cover gasket. Clean and prep the surface of the valve cover.
  8.  
  9. Clean the gasket mating surface of the cylinder head.
  10.  

To install:

  1. Apply a small bead of sealant to the corners where the camshaft journal cap meets the cylinder head.
  2.  


NOTE
Always check to ensure that the valve cover gasket is properly seated on the head.

  1. Tighten the valve cover fasteners evenly using a crisscross pattern from the inside out to 88 inch lbs. (10 Nm).
  2.  
  3. The remainder of the installation is the reverse of removal.
  4.  

4-Cylinder Engines


Click image to see an enlarged view

Fig. Location of valve cover bolts



Click image to see an enlarged view

Fig. Pull up on the valve cover to remove it



Click image to see an enlarged view

Fig. Pull up the gasket at one corner of the valve cover and carefully work your finger around the perimeter

  1. Remove the negative battery cable.
  2.  


NOTE
If the VW you are working on has a theft deterrent system be sure to have the de-activation code before you remove any of the battery cables.

  1. On 2.0L engines, detach the air intake, then remove the intake manifold. Loosen the valve cover bolts
  2.  
  3. On 1.8L engines, remove the breather hose from the valve cover. Loosen and then remove all of the fasteners.
  4.  
  5. Remove the valve cover from the cylinder head.
  6.  
  7. Remove the valve cover gasket. Clean and prep the surface of the valve cover.
  8.  
  9. Clean the surface of the cylinder head.
  10.  

To install:

  1. Install a new gasket and then the valve cover.
  2.  


NOTE
Always check to ensure that the valve cover gasket is properly seated on the head.

  1. The remainder of the procedure is the reverse of removal.
  2.  

Vr6 Engines
  1. Remove the spark plug connectors.
  2.  
  3. Detach the intake manifold cover and the intake manifold.
  4.  
  5. Remove the Positive Crankcase Ventilation (PCV) breather valve.
  6.  
  7. Remove the air intake hose from the throttle housing.
  8.  
  9. Disconnect the throttle cable.
  10.  
  11. Remove the radiator cap.
  12.  


CAUTION
Never open the radiator cap when the engine is hot.

  1. Clamp the coolant hose off at the throttle body.
  2.  
  3. Remove the oil dipstick guide tube.
  4.  
  5. Detach all necessary vacuum hoses and electrical connectors.
  6.  
  7. Remove the upper intake manifold. As a time saver leave the throttle housing connected to the intake during removal.
  8.  
  9. Remove the nuts along the perimeter of the cylinder head cover.
  10.  
  11. Lift off the cylinder head cover.
  12.  
  13. Remove the cylinder head cover gasket.
  14.  

To install:

  1. Installation is the reversal of removal. Remember to use a new gasket between the upper intake manifold and its lower portion. The cylinder head cover gasket is to be replaced if it is worn or damaged.
  2.  

 
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