Volkswagen Workshop Service and Repair Manuals

Installing –  Moisten new O-ring -arrow- with clean engine oil.

–  Check that the studs -2- are flush with the rear of the camshaft pulley. –  Fit spring cover so that the fitting hole of the cover -1- aligns with the fitting hole of the camshaft pulley. –  Screw a nut onto each stud -2- until it just contacts the cover. –  Evenly tighten both nuts against the cover until the cover securing bolts -3- can be screwed in.   Note

Ensure the studs -2- do not unscrew from the camshaft pulley. –  Tighten securing bolts -3- hand-tight. –  Remove studs -2-. Install remaining securing bolts -3- of the cover and tighten → Item. –  Check that both locating holes -1- of camshaft adjuster and exhaust camshaft pulley align with fitting holes in camshaft housing. –  Lock camshaft adjuster and exhaust camshaft pulley using locking pin -T10074- as follows:

–  First fit retaining plate -T10073- on camshaft adjuster.

–  Push locking pin -A- into fitting hole in camshaft adjuster and camshaft housing onto stop. –  Then lock exhaust camshaft pulley by pushing a locking pin -B- through second hole in retaining plate -T10073- in fitting hole of camshaft housing to stop.   Note The locking process is made easier by turning exhaust camshaft pulley slightly on securing bolt with a ring spanner until the fitting holes align. –  Install new plug with O-ring and tighten → Item. –  Remove locking pins -T10074- and retaining plate -T10073-.

–  Install engine bracket -3- and tighten → Item. –  Attach coolant hose to engine bracket. –  Install upper securing bolt -1- for lower toothed belt guard -2- and tighten → Item. –  Raise vehicle. –  Install right wheel housing liner → General body repairs, exterior; Rep. gr.66 –  Install assembly mounting and align → Chapter.

–  Tighten securing bolts -arrows- of assembly mountings → Chapter. –  Remove support bracket -10 - 222 A-. –  Install power-assisted steering reservoir. –  Install cooling system expansion tank. –  Install lower part of toothed belt guard. –  Fit engine cover.