Volkswagen Workshop Service and Repair Manuals

Removing –  Remove plenum chamber bulkhead. → General body repairs, exterior; Rep. gr.50. –  Remove air filter housing with air mass meter and connecting pipe. –  Remove cooler for exhaust gas recirculation and bypass flap. –  Remove bracket for exhaust gas recirculation cooler. –  Remove toothed belt from camshaft pulleys → Chapter.

–  Remove camshaft pulley securing bolts -1- and -2-. –  Remove camshaft pulleys from hubs.

–  Loosen hub securing bolt -1-. –  To do this, use counterhold -T10051-. –  Loosen hub securing bolt about 2 turns.

–  Fit puller -T10052- and align it with holes in hub. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.   Note When doing this, hold puller with 30 mm spanner. –  Remove hub from taper of camshaft. –  Remove exhaust camshaft hub in the same way. –  Remove cylinder head cover → Chapter. –  Remove tandem pump → Chapter.

Bolted connection for rocker arm shaft –  Loosen lock nut of adjustment screw -A- and back out screw until respective rocker arm lies against plunger spring of unit injector. –  Unscrew bolts -4, 1 and 5-, then remove bolts -2 and 3- evenly and alternately. –  Remove rocker arm shaft. –  Unscrew upper securing bolts of rear toothed belt guard.

–  Unscrew upper securing bolt -arrow- of bracket for bypass flap and exhaust gas recirculation cooler. –  Remove pre-wired wiring harness for unit injectors and glow plugs → Chapter. –  Loosen remaining 15 bolts of retaining frame equally and from the outside in. –  Screw 15 mm ejector bolts of rack -T10262- anticlockwise by hand to stop. –  Position frame -T10262- as shown on retaining frame and tighten 10 mm securing bolts to 10 Nm.

Positioning frame -T10262-. –  Screw ejector bolts clockwise by hand until they contact the cylinder head bolts. –  Now screw in ejector bolts in sequence stamped on bolt heads 1…4 equally until retaining frame is released from cylinder head. –  Remove the retaining frame. –  Remove camshafts.