Volkswagen Workshop Service and Repair Manuals

Installing l  Sealing surfaces must be free of oil and grease. l  When retaining frame or camshaft is installed, No. 1 cylinder cams must point upwards. l  The pistons must not be positioned at TDC. –  Install support elements in cylinder head and fit respective roller rocker finger onto respective valve stem end and support element.

–  Ensure that all roller rocker fingers contact valve stem ends -1- correctly and that they are clipped into their respective support elements -2-. –  Oil camshaft running surfaces.

–  Carefully lay camshaft in camshaft bearing of cylinder head (positioned for TDC No. 1 cylinder).

–  Apply an even, slightly raised sealant bead (D 188 800 A1) in clean groove of retaining frame -arrow-. Spread sealant evenly over sealing surface.   Note t  Sealant must not be applied too thickly. If necessary wipe away excess sealant with a lint-free cloth. t  The retaining frame should be positioned and bolted on without interruption because the sealant begins to harden immediately when the sealing surfaces come into contact with each other. t  Observe the use-by date of the sealing compound. –  Insert rear sealing cover flush. –  Put retaining frame in position and lightly tighten nuts for bearings 2 and 4 diagonally and alternately. Then likewise lightly tighten nuts of bearings 3, 1 and 5.

–  Finally tighten nuts in order shown to 23 Nm. –  Install cylinder head cover. Tighten bolts from inside outwards, alternately and diagonally. –  Install rear part of toothed belt guard.

–  Set seal in place using guide sleeve -T10071/1- and press in to stop using fitting sleeve -3265- and bolt -T10071/2-.   Note Put a large, commercially available washer M12 under bolt to avoid wear to fitting sleeve. –  Insert Woodruff key in camshaft.

–  Install camshaft toothed belt pulley. When tightening camshaft toothed belt pulley bolt, hold with counterhold tool 3415. Torque setting: 100 Nm.   Note When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns. Further assembly is basically the reverse of the dismantling procedure. Installing toothed belt. → Chapter   Note After fitting retaining frame and cylinder head cover, allow sealant to dry for approx. 30 minutes.