Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Engine support bracket 10-222A with legs 10-222A/1
• ◆ Counter-hold tool 3415
• ◆ 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

• ‒ First remove toothed belts
  .

• ‒ Turn the crankshaft back slightly.
• ‒ Loosen the camshaft sprockets. To do this hold camshaft sprockets with counter-hold tool 3036.
• ‒ → Set camshaft sprockets so that the markings align as shown.
• ‒ Remove camshaft sprockets.
• ‒ Remove cylinder head cover.
• ‒ Remove distributor.

Inlet camshaft

• ‒ → First remove bearing caps 0, 1 and 3 as well as the distributor securing cap.
• ‒ Then slacken off bearing caps 2 and 4 alternately and diagonally.

Exhaust camshaft

• ‒ First remove bearing caps 5, 6 and 8.
• ‒ Then slacken off bearing caps 7 and 9 alternately and diagonally.

Installing

Conditions

• ● The pistons must not be positioned at TDC.

Note:

Note the fitting position of the bearing cap: The point -arrow- must point to the exhaust side.

• ‒ Oil the camshaft contact surfaces.
• ‒ Fit the camshaft so that the toothed belt sprocket recesses are opposite one another (top dead centre No. 1 cylinder).

Inlet camshaft

• ‒ → Tighten bearing caps 2 and 4 alternately and diagonally and then tighten to
       6 Nm.
• ‒ Lightly coat contact surface of bearing cap 0 and distributor securing cap with sealant AMV 174 004 01.

• ‒ Install bearing caps 0, 1 and 3 and also the distributor securing cap and also tighten to
       6 Nm.
  When doing this insert distributor for centralizing securing cap.
• ‒ Turn all nuts by 1/4 turn (90 °) further.

Exhaust camshaft

• ‒ Tighten bearing caps 7 and 9 alternately and
  diagonally and then tighten to
       6 Nm.
• ‒ Coat bearing cap 5 seating areas lightly with sealant AMV 174 004 01.
• ‒ Install bearing caps 5, 6 and 8 and also tighten to
       6 Nm.
• ‒ Turn all nuts by 1/4 turn (90 °) further.
• ‒ Install camshaft sprockets.
• ‒ Hold the respective camshaft sprocket with counter-hold tool 3036 and tighten to
       20 Nm
  and then turn bolt
       1/4 turn (90 °) further.

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

Installing toothed belt and adjusting timing => Page 13-12 .

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).