Removal
Bring the engine to TDC.
Remove the timing belt and camshaft gear, removing and installing the timing belt, tensioning.
Left cylinder head
Remove the cylinder head cover.
Loosen mounting bolts 1 and 2 and remove the rear timing belt cover (fig. 2.126).
Right cylinder head
Remove the cylinder head cover.
Remove diverter roller 1.
Unscrew the mounting bolts (see fig. 2.127) and remove the rear timing belt cover.
Disconnect the plug from the Hall sensor and remove the housing together with the plug and cone.
Check the TDC position of the camshafts. The marks on the camshafts should match both arrows on the bearing cap (fig. 2.128).
When continuing to use the old camshaft drive roller chain.
Mark the roller chain before removing (fig. 2.129) (eg paint an arrow indicating the direction of chain movement).
NOTE: Do not mark the chain with a core marker or leave any notches.
Secure the valve timing adjuster using the 3366 chain tensioner holder (fig. 2.130).
NOTE: If the chain tensioner is too tight, the camshaft adjuster may be damaged.
Mark the mounting position and sequence of the bearing caps as shown in the figure, regardless of the designation applied to them (for example, with a waterproof marker).
Remove the valve timing adjuster mounting bolts.
Remove bearing cap 1.
Remove bearing caps 2, 4, 6, 8 and 9 and in accordance with the removal sequence (fig. 2.131).
Unscrew bearing caps 3, 5 and 7 one by one in a crosswise pattern and remove them.
Remove both camshafts with the valve timing adjuster and place them on a clean surface.
Installation
Replace the semi-circular plug.
Replace the valve timing adjuster gasket.
Lightly lubricate the sewn-in surface with sealant AMV 188 001 02 (fig. 2.132).
Place the roller chain on the camshaft drive gears as follows.
When continuing to use the old camshaft drive roller chain.
Align the marks (fig. 2.129).
When using a new camshaft drive chain
The distance between grooves A and B should be 16 chain rollers. The figure shows where rollers 1 and 16 should be installed on the toothed wheels. Chain rollers 1 and 16 are offset opposite grooves A and B by 1/2 tooth width to the left (fig. 2.133).
Insert the valve timing adjuster between the camshaft drive roller chain.
Place the camshafts with the roller chain and valve timing adjuster on into the cylinder head.
Lubricate the camshaft grooves with engine oil.
NOTE: The fitted bushings for the bearing caps and camshaft adjuster must be inserted into the cylinder head.
Install bearing caps 3, 5 and 7 in accordance with the designation and tighten with new bolts, alternating crosswise. Tightening torque: 5 Nm + further tighten by 1/4 turn (90°).
Screw on the valve timing adjuster 10. Tightening torque: 5 Nm + an additional 1/4 turn (90°).
Install the chain tensioner.
Check the TDC position of the camshafts. The marks on the camshafts should match both arrows on the bearing cap (fig. 2.134).
NOTE: To align the marks, rotate the camshaft forward and backward slightly if necessary.
Lightly lubricate the double bearing cap 6 and the bearing cap 1 with sealant AMV188 001 02 and install both caps. Tightening torque: 5 Nm + 1/4 turn further (90°).
Install the remaining bearing caps. Tightening torque: 5 Nm + 1/4 turn further (90°).
Replace the camshaft seals.
Replace the Hall sensor seals.
Carefully press the cover using the stop of the clamping sleeve 3202.
(The original text can be found on the portal vwmanual.ru)
Further installation is carried out in reverse order.
NOTE: After installing the camshafts, the engine must not be started for approximately 30 minutes. The hydraulic lifters must be seated. (Otherwise, the valves will touch the pistons). After working on the valve train, crank the engine by hand to make sure that none of the valves are touching the piston.
Before installation, apply a small amount of sealant AMV 188 001 02 to the joints of the front and rear bearing covers (fig. 2.135).
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