- generously lubricate the valve stems with engine oil and insert them into the corresponding guide bushings;
Fig. 49. Installing the oil deflector cap: 1 - plastic sleeve; 2 - oil deflector cap; 3 - special tool 3129
- using special tool 3 (Fig. 49), install oil deflector caps 2, for which:
- place the plastic sleeve 1 of the special tool 3129 onto the protruding part of the valve guide sleeve;
- lubricate the oil deflector cap well with engine oil and place it on the plastic sleeve;
- place special tool 3129 on the valve stem seal and gently press on the guide sleeve;
Note: Installing the valve stem seals without using special tool 3129 may damage them, resulting in increased oil consumption.
- if the valves have been lapped, each valve must be installed in the seat to which it was lapped;
Fig. 37. Valve drive mechanism parts: 1 - hydraulic pusher; 2 - valve stem halves (crackers); 3 - upper valve spring plate; 4 - valve springs; 5 - oil deflector cap; 6 - valve guide bushing; 7 - cylinder head; 8 - valves; a - cylinder head height
- install one inner and outer spring 4 (Fig. 37) for the corresponding valve into the cylinder head holes (if old springs are installed);
Fig. 36. Removing valves using a special device from the company "Volkswagen"
- put on the upper plate 3 of the valve spring. Install the valve puller (Fig. 36) in order to compress the springs. If the end of the valve stem protrudes from the upper plate of the valve spring, then you need to install both halves of the valve stem 2 (Fig. 37) in the stem seat and smoothly press on the valve puller;
- insert the hydraulic tappets into the holes according to the marks made earlier, after lubricating them with engine oil;
- generously lubricate the journals with engine oil (bearing locations) camshafts;
- place the camshafts in the cylinder head supports and rotate them several times. Orient the camshafts so that both cams of the first cylinder on the two shafts are facing upwards;
- install both camshafts into the cylinder head as follows.
Mounting the camshaft of cylinder banks 1, 3 and 5
Fig. 31. Components of camshafts together with bearing caps and sprockets: 1 - camshaft bearing cap; 2 - nut, 20 Nm; 3 - camshafts; 4 - camshaft sprockets; 5 - Hall sensor drive mechanism; 6 - bolts, 100 Nm
Fig. 34. Numbering of camshaft bearing caps. Each cap has an arrow indicating the direction of installation
Fig. 50. Numbering of camshaft bearing caps
Generously lubricate the inside of the bearing caps with engine oil and install bearing caps 3 and 5 (Fig. 34) and bearing caps 1 (Fig. 31) of the camshaft on the cylinder head in accordance with Fig. 50:
Note: The numbers on the installed bearing caps should be read from the exhaust pipe side and the arrows on the installed caps should point towards the crankshaft flywheel.
- tighten the four nuts alternately, crosswise in several stages and tighten them to a torque of 20 N·m. Due to the uniform tightening, the valve springs will be slowly compressed, and thus it will be possible to avoid camshaft distortion;
- install bearing caps 1 and 7 in the same manner;
- turn the camshaft several times to make sure it is not jammed anywhere.
Mounting the camshaft for cylinder banks 2, 4 and 6
Generously lubricate the inside of the bearing caps with engine oil and install bearing caps 2 and 6 (Fig. 34) and bearing caps 1 (Fig. 31) of the camshaft on the cylinder head, in accordance with Fig. 50:
Note: The numbers on the installed bearing caps should be read from the exhaust pipe side and the arrows on the installed caps should point towards the crankshaft flywheel.
- tighten the four nuts alternately, crosswise, in several stages and tighten them to a torque of 20 N·m. Due to the uniform tightening, the valve springs will be compressed slowly, and thus it will be possible to avoid camshaft distortion;
- install bearing cover 4 in the same way;
- turn the second camshaft several times to make sure it is not pinched anywhere;
- put the sprockets on the camshafts. The sprockets should be installed on the same shafts they were on before disassembly. Make sure that the sprockets are secured with stoppers;
- install the Hall sensor drive mechanism link 5 on one of the camshafts (Fig. 31);
- install the sprockets 4 (Fig. 31) of the drive onto the camshafts. The contact surfaces of the carrier and the sprocket of the drive must be dry;
Fig. 32. Fixing the camshafts. The arrows show the hexagons used to fix the camshafts
- tighten bolts 6 (Fig. 31) securing the sprockets, fix the camshafts in a stationary position using hexagons (Fig. 32) and tighten both bolts securing the sprockets to a tightening torque of 100 N·m. After this, unlock the camshafts;
- clean the surface of the camshaft cover and apply sealant AMV 188 002 02 to it;
- install the cover. First tighten the bolts one by one by hand, then tighten them in a circle with a tightening torque of 10 N·m. Check whether the O-ring, which should be in the cover, is inserted from the inside of the cover;
Fig. 51. Cleaning the holes. The arrow shows the places where the holes with a diameter of 3 mm need to be cleaned
- if both camshafts (or just one camshaft) were removed with the engine installed, then before installing the camshaft cover, you need to clean both three-millimeter holes (fig. 51, shown by arrows) in the cylinder head cover and lubricate with sealant AMV 188 002 02;
- install ignition coil;
- install all previously removed parts on the cylinder head, the number of which depends on the volume of repair work being carried out. With the exception of parts that are installed during the installation of the cylinder head in order not to do the same job twice.
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