Removing
Remove the air filter.
Remove the top casing of a gear belt.
Remove the cylinder head cover.
Insert the crankshaft into the cylinder position.
Attention! After that, do not change the position of the motor shafts.
Loosen and remove the toothed belt only from the top of the toothed pulley 16 (pic. 167) camshaft.
Pic. 167. Gas distribution mechanism: 1 - camshaft; 2 - bearing caps (pay attention to the offset of the holes from the center); 3 - adjusting washer; 4 - pusher; 5 - the upper cup of the valve spring (distinguishing feature: wide external chamfer; narrow internal chamfer); 6 - outer and inner valve springs; 7 - oil scraper cap; 8 - lower valve cup; 9 - valve guide sleeve; 10 - plug; 11 - sealing ring; 12 - valves; 13 - insert for the nozzle (ONLY FOR GTI) - 20 Nm (coat threads with sealant D6); 14 - stuffing box; 15 - cylinder head; 16 - key; 17 - pulley
Lock the camshaft sprocket from the front with a metal rod. Turn away a gear pulley of a camshaft. Remove the camshaft key.
Mark bearing caps 1, 2, 3, etc. (see fig. 168).
Remove the bearing caps 1, 3 and 5. Then loosen the bolts of the bearing caps 2 and 4 alternately crosswise.
Remove the camshaft. The camshaft pulley is mounted on the conical part of the shaft and, after unscrewing the bolt, is removed from the cone with light blows of a rubber hammer.
Attention! Since February 1984, install a sealed timing belt cover. On these vehicles, the camshaft pulley will be removed from the cone by hitting a drift with a hammer inserted into a D6 mm hole in the rear casing.
Attention! If it is necessary to remove the washers to adjust the valve clearances, they should be marked in order to subsequently install them in their original places.
Installation
Attention! Cylinder heads are partially supplied with camshaft bearing shells. There are two different designs available: Cylinder heads with redesigned camshaft bearings with normal sized camshaft (diameter 26.00 mm), and cylinder heads with reduced bearing journals (undersized camshaft with a diameter of 25.75 mm and a yellow marking dot on the VW-AUDI emblem).
The undersized camshaft is not available as a spare part. In the event of a repair, a normal-sized camshaft with appropriate bearings is installed.
Camshaft runout may be checked before installation at a service station. Wear limit: 0.01 mm.
When installing engines with significant mileage or with noise in the valve mechanism, it is advisable to check the axial play. Wear limit: 0.15 mm. The measurement is made with the poppets removed and the bearing caps 1 and 5 installed.
Insert a new camshaft seal. Lightly lubricate the sealing lip and the outer edge of the oil seal with engine oil beforehand.
Replace plug if damaged.
Test the bearing caps and note the offset from the center of the holes. Bearing caps must be installed so that the holes in the bearing caps and in the cylinder head match. Pay attention to the markings on the bearing caps.
If the poppet pushers were removed, put them in their original places in accordance with the marking. Insert the bucket tappets lightly lubricated with engine oil and do not skew them.
Attention! Do not confuse poppet pushers.
If the adjusting washers were removed, insert them into their original places lubricated with engine oil. Observe labelling.
Attention! The inscription on the shim must face up.
Lubricate with engine oil and insert the camshaft.
Attention! In this case, the cams of the 1st cylinder must be turned upwards.
Install according to bearing cap markings. Pay attention to offset holes. Alternately and crosswise tighten the bearing cap bolts 2 and 4 with a torque wrench. Tightening torque 20 Nm.
Install bearing caps 1, 3 and 5 and tighten screws to 20 Nm.
Insert the camshaft key. Put on and tighten to 80 Nm the gear pulley of the distributor-south shaft. Lock the camshaft sprocket with a metal rod.
Place the toothed belt on the camshaft sprocket. Pay attention to the correct installation of the intermediate shaft and the toothed belt pulley.
Tension the toothed belt.
Attention! When installing a new camshaft, check and, if necessary, adjust the valve clearances on the engine.
Install new cylinder head cover gaskets, carefully tighten the cylinder head cover bolts to 10 Nm.
Install the toothed belt guard.
Install the air filter.
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