Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 10-222A Engine support bracket with legs 10-222A/1
• ◆ 2064 Mandrel (for single-part injection pump sprocket)
• ◆ 2065 A Setting bar
• ◆ 3036 Counter hold tool
• ◆ 3359 Mandrel for diesel injection pump (for two-part injection pump sprocket)
• ◆ 3387 Pin wrench

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ AMV 174 004 01 Sealant
• ◆ Punch
• ◆ Feeler gauge

Removing

• ‒ Take toothed belt off camshaft sprocket and remove camshaft sprocket , Removing, installing and tensioning toothed belt.

Note:

It is not necessary to remove ribbed belt, vibration damper/belt pulley and lower toothed belt guard.

• ‒ First remove bearing caps 5, 1 and 3. Then 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.
• ‒ Lightly coat contact surface of ends of bearing cap 1 with sealant AMV 174 004 01.
• ‒ Install bearing caps 5, 1 and 3 and also tighten to
       20 Nm.
• ‒ Locate bearing cap 5 by tapping lightly on the end of the camshaft.

The rest of the assembly is basically a reverse of the dismantling sequence.

• ‒ Fit camshaft sprocket together with toothed belt and attach with securing bolt (camshaft sprocket may still be turned).

Installing toothed belt and adjusting timing => Page 15-11 , Removing, installing and tensioning toothed belt.

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).