Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Remove toothed belt guard upper part.
• ‒ Loosen camshaft sprocket (counter-hold with 3036).
• ‒ Set camshaft sprocket to TDC No. 1 cylinder mark by turning the crankshaft.

→ Engine codes AAM, ABS, ADZ

Mark on camshaft sprocket must align with arrow on toothed belt guard.

→ Engine code 2E, ADY, AGG

•      A -     Cylinder head cover fitted

Arrow on cylinder head cover must align with mark on camshaft sprocket.

•      B -     Cylinder head cover removed

Mark on camshaft sprocket must align with cylinder head.

Continued for all engine codes

• ‒ Remove cylinder head cover.
• ‒ Release tensioner and take off toothed belt.
• ‒ Pull off camshaft sprocket.
• ‒ Remove woodruff key from camshaft.
• ‒ First remove bearing caps 1 and 3.
• ‒ Slacken off bearing caps 2 and 5 alternately and diagonally.

Installing

Notes:

• ◆ When installing the camshaft No. 1 cylinder cams must point upwards.

• ◆ → When installing the bearing cap note offset, before installing camshaft fit bearing caps and determine fitting position.

• ‒ Oil camshaft running surfaces.
• ‒ Tighten bearing caps 2 and 5 alternately and
  diagonally to
       20 Nm.
• ‒ Install bearing caps 1 and 3 and also tighten to
       20 Nm.
• ‒ Install camshaft sprocket and tighten to
       80 Nm
  (counter-hold with 3036).
• ‒ Install and tension toothed belt (adjusting valve 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).