Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Set engine to TDC No. 1 Cyl. marks by turning in engine direction of rotation on the vibration damper securing bolt , checking valve timing.
• ‒ Remove cylinder head cover .
• ‒ Remove ignition transformer (N152).

=> Repair group 28; Motronic injection and ignition system; Servicing ignition part

• ‒ Remove chain tensioner for camshaft chain.
• ‒ Remove camshaft sprocket cover with Hall sender (G40).

• ‒ Loosen securing bolts for camshaft sprockets.

→ Note:

Only counter-hold camshaft with 24 mm OJ spanner -arrow-. The camshaft jig 3268 must not be in place when tightening or loosening the chain sprockets.

• ‒ Remove camshaft sprockets.

• ‒ → Mark camshaft chain before removing (e.g. with paint, arrow pointing in D.O.R.).

Notes:

• ◆ From engine number AAA-217001 or ABV-021781 camshaft drive single chains only are installed.
  Therefore the chain tensioner has no oil drilling and must not be bled.
• ◆ Do not mark chain with a punch mark, notch or similar!

→ Camshaft cylinder bank 1, 3 and 5

• ‒ First remove bearing caps 1 and 7.
• ‒ Slacken off bearing caps 3 and 5 alternately and diagonally.

Camshaft cylinder bank 2, 4 and 6

• ‒ First remove bearing cap 4.
• ‒ Slacken off bearing caps 2 and 6 alternately and diagonally.

Installing

• ‒ Oil running surfaces of both camshafts.

Notes:

• ◆ Observe marking (direction of rotation) of chain!

• ◆ → When installing the camshafts the recess for the camshaft sprockets -arrows- must be at top.
• ◆ When installing bearing caps ensure that the identification mark is readable from the exhaust side of cylinder head and that the arrow points to vibration damper end.

Camshaft cylinder bank 1, 3 and 5

• ‒ Tighten bearing caps 3 and 5 alternately and
  diagonally to
       20 Nm.
• ‒ Install bearing caps 1 and 7 and also tighten to
       20 Nm.

Camshaft cylinder bank 2, 4 and 6

• ‒ Tighten bearing caps 2 and 6 alternately and
  diagonally to
       20 Nm.
• ‒ Install bearing cap 4 and also tighten to
       20 Nm.
• ‒ Clean sealing surfaces of cover for camshaft sprockets and cylinder head.

• ‒ → Remove old sealant from 3 mm holes in cylinder head gasket -arrows-.

Note:

With the cylinder head installed the holes in the cylinder head gasket are only half visible.

• ‒ Install camshaft chain sprockets with chain , adjusting valve timing.
• ‒ Fill 3 mm holes in cylinder head gasket with sealant AMV 188 001 02.
• ‒ Coat sealing surfaces of cover for camshafts with AMV 188 001 02.
• ‒ Oil O-ring (=> Page 15-4 , Pos. 13 ) and insert in cover for camshaft sprockets.
• ‒ Install cover for camshafts, insert old securing bolts and tighten lightly.
• ‒ First tighten M8 securing bolts to
       25 Nm
  then tighten M6 securing bolts to
       10 Nm.
• ‒ Install chain tensioner for camshaft chain and tighten to
       30 Nm.

Notes:

• ◆ If the chain tensioner for double chain has been pulled apart, bleed chain tensioner before installing
  , Fig. 3 .
• ◆ 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).