Camshaft oil seal replacement
The camshaft seal is replaced without removing the shaft from the cylinder head.
1. Remove the toothed belt as described earlier. Loosen and remove the camshaft sprocket bolt, remove the sprocket and key.
2. Remove the old oil seal from its socket in the cylinder head using a special puller (pic. D:10) or carefully pry it out with a screwdriver/wire hook.
3. Make sure the oil seal seat in the cylinder head is undamaged and clean. Lubricate the lip and outer edge of the new oil seal with engine oil.
4. Insert the oil seal into the hole and, using the special tool, (pic. D:12) press it in so that it is flush with the cylinder head. As a mandrel, you can use the head of a socket wrench of a suitable diameter. Install the gland evenly, without distortion.
ATTENTION: Do not press in the stuffing box to the stop, because this will close the oil return channel.
5. Reinstall previously removed parts. Adjust the tension of the toothed belt and alternator belt as described earlier.
Removing the camshaft
1. Remove the valve cover. Note the location of the detachable vacuum hoses. On some models, the air filter must be removed to gain access to the cylinder head.
2. Set the crankshaft to the TDC position of the compression stroke of the 1st cylinder, then remove the toothed belt and related parts as described earlier.
3. Remove the camshaft sprocket and key.
4. Remove the middle and two outer camshaft bearing caps (those. bearing caps Nos. 1, 3, and 5 - fig. D:13). Gradually, in a diagonal sequence, loosen the nuts securing the two remaining (Nos. 2 and 4) covers, then remove the covers. Arrange the covers in order and remember their position in relation to the cylinder head, because. covers can only be installed in one position.
ATTENTION: The camshaft oil seal, installed in bearing No. 1, will be displaced from its place when the cover is removed. When installing the shaft, a new oil seal must be installed.
5. Remove the camshaft, being careful not to lose the shims located on top of each pushrod.
Installing the camshaft
1. Align the alignment marks on the crankshaft pulley and auxiliary shaft sprocket (rice. D:6), while the rotor of the ignition distributor must be aligned with the mark of cylinder No. 1 on the housing.
2. If the timing belt bottom cover is installed (on models with two toothed belt covers), it is impossible to see the alignment mark on the auxiliary shaft sprocket. In this case, make sure that the TDC mark on the flywheel or drive plate is aligned with the pointer in the inspection hole in the clutch housing (pic. D:44).
3. Install the camshaft in the cylinder head with the lobes of cylinder #1 facing up.
4. Install the camshaft bearing caps. Make sure the covers are installed in the only correct position (pic. D:17). Evenly, in a diagonal sequence, tighten the bearing cap nuts #2 and #4 (pic. D:13) with a moment of 2.0 kGm. After that, tighten the nuts of the remaining bearing caps (Nos. 1, 2 and 3). Before tightening the cover E, install it completely into place by tapping lightly on the end of the camshaft.
5. Check the axial play of the camshaft using a dial indicator (pic. D:18). The axial play must not exceed 0.15 mm. Check the axial play by installing only the bearing caps No. 1 and 5 and removing the valve lifters.
Install a new camshaft oil seal into the #1 bearing hole as previously described. Install the rest of the previously removed parts. On fig. D:11 shows the details of the camshaft drive.
Camshaft identification
Depending on the type and date of manufacture of the engine, the camshaft can be one of several modifications. Different camshafts have different shapes and cam heights and provide different valve timing.
Camshaft early engines 1.5 l (1471 cm3) has a cast ring on the first cam (Ah, fig. D:14).
Camshaft engines 1.6 l (1588 cm3) and later engines 1.5 l (1457 cm3) has cast rings on the first and third cams (B, fig. D:14). The same camshaft was installed on injection engines of early releases (Ah, fig. D:15).
Starting from December 1979, a camshaft with modified valve timing, indicated by the letter "G" between cams of the 1st cylinder (B, fig. D:15).
When replacing a camshaft, make sure that you have purchased a new shaft of the correct modification.
Some cylinder heads are supplied as spare parts with undersized camshafts. These shafts are fitted with bearing shells and can be identified by the yellow spot on the VW/Audi logo.
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