Contents: Removal ↓ Installation ↓
4-cylinder 8-valve engine
Removal
Remove the air filter, see chapter "Power supply system".
Remove the upper timing belt cover, see above.
Remove cylinder head cover 9. Set the crankshaft to the TDC position for cylinder 1, see chapter "Ignition system".
Note: Do not change the engine adjustment any further.
Loosen the timing belt and remove it from the camshaft timing gear only, see above.
Lock the camshaft gear at the front using a punch. Unscrew and remove the gear; if it does not give in, tap it lightly with a rubber hammer. Remove the woodruff key.
Mark all bearing caps, see figure.
Remove covers 1 and 3. Then crosswise release covers 2 and 4.
Diesel engine: First remove covers 5, 1 and 3. Then crosswise loosen covers 2 and 4.
Remove the camshaft.
Note: If the plate tappets need to be removed, they must be marked so that they can be installed in the same place when installed. Plate tappets with the working surface (camshaft side) lay down.
Installation
The camshaft is marked by embossing numbers and letters between the intake and exhaust cams.
Please note: Replacement cylinder heads are sometimes supplied with bearing shells for the camshaft. There are 2 different versions: 1 - cylinder head with cleanly machined bearing beds, camshaft for camshaft of nominal size (diameter a = 26.00 mm, for AEK engine: a = 25.97 mm, for AFT, AGE engines: a = 34.00 mm). 2 - cylinder head with cleanly machined bearing beds of the camshaft and camshaft with journal diameter smaller than nominal (diameter smaller than nominal a = 25.75 mm and yellow paint dot on VW-AUDI designation). Camshaft with journal diameter smaller than nominal is not supplied as a spare part, if necessary, install camshaft with nominal journal diameter and corresponding bearing shells.
If necessary, the camshaft can be checked for runout in the workshop before installation. Wear limit: 0.01 mm.
If a used camshaft is reinstalled on engines with high mileage or noisy valve train, it is advisable to check its axial clearance. The wear limit is 0.15 mm. The measurement is performed with the disc tappets removed and bearing caps 1 and 4 installed, for diesel engines - 1 and 5
Install a new camshaft oil seal. Before installation, lightly lubricate the working edge and outer edge of the seal
The plug must be replaced.
Install bearing caps as a test and pay attention to the offset of the mounting holes relative to the center. The bearing caps must be installed so that the holes in the caps coincide with the holes in the cylinder head. Pay attention to the markings on the bearing caps.
If the plate tappets have been removed, they should be installed in the same places. The tappets are easy to lubricate and should not be skewed during installation.
Caution: The tappets cannot be interchanged.
Lubricate the camshaft and insert it.
Note: The cams of cylinder 1 must point upwards. Install the bearing caps in accordance with the marking. Pay attention to the offset of the middle: tighten caps 2 and 4 crosswise with a torque of 20 Nm.
Install bearing caps 1 and 3 and tighten to 20 Nm.
Diesel engine: install bearing caps 5, 1 and 3 and tighten to 20 Nm. At the same time, adjust bearing cap 5 to the end surface of the camshaft using light blows of a plastic hammer.
Insert the camshaft gear segment key. Put on the camshaft gear and tighten to a torque of 80 Nm. At the same time, hold the camshaft gear wheel with a punch.
Place the timing belt on the camshaft gear. Pay attention to the correct position of the intermediate shaft and belt pulley, see above.
View the original on this resource: VWmanual.ru
Tighten the toothed belt, see above.
Replace the cylinder head cover gasket with a new one, carefully tighten the cover bolts to a torque of 10 Nm. In a carburetor engine, secure the fuel settling chamber bracket together with the cylinder head cover.
Install the timing belt cover.
Caution: If new bucket tappets are installed, the engine must not be started for approximately 30 minutes, otherwise the valves will collide with the pistons.
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