Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Counter-hold tool 3036
• ◆ Torque wrench V.A.G 1331 (5 - 50 Nm)
• ◆ Torque wrench V.A.G 1576 (75 - 400 Nm)

Removing

• ‒ Remove toothed belt guard upper part.
• ‒ Loosen camshaft sprocket (counter-hold with 3036).

• ‒ → Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must align with arrow on toothed belt guard.
• ‒ Release tensioner and take off toothed belt.
• ‒ Remove upper part of intake manifold and cylinder head cover.
• ‒ Pull off camshaft sprocket.
• ‒ Remove woodruff key from camshaft.
• ‒ First remove bearing caps 1, 3 and 5. Loosen bearing caps 2 and 4 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 4 alternately and
  diagonally to
       20 Nm.
• ‒ Install bearing caps 1, 3 and 5 and also tighten to
       20 Nm.
• ‒ Insert woodruff key in camshaft.
• ‒ 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).