Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Counter-hold tool 3036
• ◆ Torque wrench V.A.G 1331 (5...50 Nm)
• ◆ Torque wrench V.A.G 1332 (40...200 Nm)
• ◆ Sealing compound AMV 174 004 01

Removing

• ‒ Remove toothed belt guard upper part, intake manifold upper part and cylinder head cover.
• ‒ Loosen camshaft sprocket (counter-hold with 3036).

• ‒ → Set camshaft to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must align with cylinder head.
• ‒ Release tensioner and take off toothed belt.
• ‒ Pull off camshaft sprocket.
• ‒ Remove distributor.
• ‒ Mark inlet camshaft drive chain before removing (e.g. with a painted arrow showing D.O.R.).

Note:

Do not mark chain with a centre punch or any similar means!

Inlet camshaft

• ‒ → Remove bearing caps 5 and 7, and the last one.
• ‒ Slacken off bearing caps 6 and 8 alternately and diagonally.

Exhaust camshaft

• ‒ Remove bearing caps 1 and 3, and the first and last ones.
• ‒ Slacken off bearing caps 2 and 4 alternately and diagonally.

Installing

Conditions

• ● The pistons must not be positioned at TDC.

• ‒ Oil the camshaft contact surfaces.

• ‒ → Install camshafts with chain so that the marks on the sprockets align -arrows-.

Notes:

• ◆ Observe D.O.R. marking.
• ◆ When installing bearing caps ensure that the recesses on the caps face towards the intake side of the cylinder head -Fig. V15-0650-.

Inlet camshaft

• ‒ Tighten bearing caps 6 and 8 alternately and
  diagonally to
       15 Nm.
• ‒ Install remaining bearing caps and tighten to
       15 Nm.

Exhaust camshaft

• ‒ Tighten bearing caps 2 and 4 alternately and
  diagonally to
       15 Nm.
• ‒ Lightly coat bearing cap contact surface on camshaft sprocket and on distributor cap with sealing compound AMV 174 004 01.
• ‒ Install remaining bearing caps and tighten to
       15 Nm.
• ‒ Install camshaft sprocket and tighten to
       65 Nm
  (counter-hold with 3036).

The rest of the assembly is basically a reverse of the dismantling sequence.

Installing toothed belt and adjusting timing .

Note:

When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).