Replacing the camshaft without removing the engine (VW Golf 2)

Removal the camshaft on the engine installed in the car is carried out as follows:

When turning the crankshaft, set the pistons so that none of them is at TDC.

Remove the valve cover.

Remove the bolts securing the toothed pulley to the camshaft (the pulley must be well locked).

Partially drain the cooling system, loosen the pump housing fastening as described above. Remove the timing belt and toothed pulley from the camshaft. Remove the ignition system components. Remove the fuel pump from a carburetor engine.

Remove bearing caps Nq 1, 3, 5 (see figure 42), gradually unscrewing the nuts in turn on each side. On the front cover, also unscrew both bolts.

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Loosen the nuts securing the bearing caps 2 and 4 evenly in a crisscross pattern until both caps are disconnected. Remove the caps and take out the camshaft. Before putting the caps aside, they should be inspected. The wide protrusion (see "A" figure 42) is located on the intake manifold side, the cover number (B) must also be read from the intake manifold side.

If necessary, the tappets can be removed. They should not be swapped and it is recommended to mark them. This is best done with strokes on the inside (see figure 43), marking the first tappet with one line, the second with two lines, etc. The removed tappets should lie on the end surface interacting with the cams so that oil does not leak out of them. The tappets should be removed from the drive side.

Installation the camshaft is produced as follows:



Lubricate the shaft bearing journals with engine oil and insert the shaft into place.

Take the bearing caps one by one and determine which side has the wide protrusion "A" (see figure 42). This projection should be directed towards the intake manifold. Install the covers in the correct order. The letters "B" should also be read from the intake manifold side.

Make sure that none of the pistons are at TDC. Tighten the bolts securing covers 2 and 4 to 6 Nm in a "crisscross" pattern; cover bolts No.1, 3, 5 with a torque of 6 Nm. Tighten all bolts in turn by an additional 1/4 turn (90°).

Install both bolts (see figure 94) and tighten to a torque of 10 Nm.



Reinstall the toothed pulley as described previously and perform all other operations in the reverse order of disassembly.

Caution: If new hydraulic tappets have been installed, the engine must not be started for 30 minutes, otherwise the valves may come into contact with the pistons.