Volkswagen Workshop Service and Repair Manuals

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

• ◆ 10-222A Support bracket
• ◆ 10-222A/1 Support for support bracket
• ◆ T 10028 Counter-hold
• ◆ T 10016 Camshaft locking device
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)
• ◆ D 188 003 A1 Sealant

Removing

Notes:

• ◆ The camshafts are mounted in the camshaft housing on this engine. Therefore the camshaft housing can only be removed after first removing both toothed belts.
• ◆ The camshaft housing sealing surface must not be reworked.
• ◆ Removing and installing camshaft , Servicing valve gear.

Work sequence

• ‒ First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ First remove both toothed belts
  .
• ‒ Remove spark plug connectors with H.T. cables.
• ‒ Pull 4 pin connector off ignition transformer.
• ‒ Pull connector off Hall sender.

• ‒ → Remove securing bolts from exhaust gas recirculation valve -1- as well as cable retainer -2-.
• ‒ Remove toothed belt guard rear securing bolt (in area of right-hand lifting eye).
• ‒ Loosen camshaft housing bolts (from outside to inside and in cross-over sequence) and remove.
• ‒ Carefully lift camshaft housing off.

Installing

Prerequisites

• ● The crankshaft toothed belt sprocket is secured to the crankshaft with the securing bolt and two washers.
• ● The pistons must not be positioned at TDC.
• ● Camshaft sprockets locked into camshaft housing fitting holes with T 10016 and secured against turning.

Note:

If a piston is at TDC the valves could strike the piston when turning the camshafts.

• ‒ Remove sealant remnants on cylinder head and camshaft housing with a commercially available sealant remover.
• ‒ Prevent dirt and sealant remnants from entering cylinder head.

• ‒ Clean sealing surface, must be free of oil and grease.
• ‒ → Apply a thin even coat of sealant onto the clean camshaft housing sealing surface. See hatched area on illustration.

Note:

The sealant must not be applied too thick otherwise excess sealant can enter the oil channels and cause damage to the engine.

• ‒ → Ensure all roller rocker fingers contact the valve ends -1- correctly and they are clipped into their respective support elements -2-.
• ‒ Screw two studs (M6 x 70) into cylinder head before installing camshaft housing.

• ‒ → Carefully fit the camshaft housing vertically onto the cylinder head studs and dowel pins -arrows- from above.
• ‒ Tighten camshaft housing new securing bolts (evenly from inside to outside using cross-over sequence).

Ensure that camshaft housing is not canted.
     Tightening torque: 10 Nm + 1/4 turn (90 °) further.

Note:

• ◆ Sealant must be left dry for approx. 30 minutes after installing camshaft housing.

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