Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Remove air cleaner.
• ‒ Remove upper part of toothed belt guard.
• ‒ Remove cylinder head cover.
• ‒ Set crankshaft to TDC on No. 1 cylinder.
• ‒ Slacken off and remove toothed belt.
• ‒ Remove camshaft sprocket (counterhold with 3036).
• ‒ Take Woodruff key out of camshaft.

Engines with hydraulic valve clearance compensation

• ‒ First remove bearing caps 1 and 3. Loosen bearing caps 2 and 5 alternately and diagonally.

Engines with no hydraulic valve clearance compensation

• ‒ First remove bearing caps 1, 3 and 5. Loosen the bearing caps 2 and 4 alternately and diagonally.

Installing

Note:

• ◆ The cams for No. 1 cylinder must face upwards on installing the camshaft.

• ◆ → When installing the bearing caps, note the centre offset of the bore; before installing, fit the bearing caps and find the correct position.
• ◆ Pistons should not be at TDC on turning the camshaft. Danger of valve/piston crown damage.

• ‒ Lubricate bearing surfaces.

Engines with hydraulic valve clearance compensation

• ‒ Tighten bearing caps 2 and 5 alternately and diagonally.
       Tightening torque: 20 Nm
• ‒ Install bearing caps 1 and 3.
       Tightening torque: 20 Nm

Engines with no hydraulic valve clearance compensation

• ‒ Tighten bearing caps 2 and 4 alternately and diagonally.
       Tightening torque: 20 Nm
• ‒ Install bearing caps 5, 1 and 3.
       Tightening torque: 20 Nm
• ‒ Insert Woodruff key in camshaft.
• ‒ Fit and tighten camshaft (counterhold with 3026)
       Tightening torque: 80 Nm
• ‒ Install toothed belt (adjust valve timing)

Note:

• ◆ When new hydraulic bucket tappets have been installed, the engine must not be started for approx. 30 minutes. Hydraulic compensation elements must be allowed to settle. (Valves would otherwise strike pistons).
• ◆ When installing a new camshaft, check valve clearance with engine cold and adjust if necessary (engines with no hydraulic valve clearance compensation only) => page 15-36 .