Removal
Disassemble the engine crankcase.
Pull out the camshaft. Pay attention to the stuck bearing shells, which may fall.
Remove and mark the bearing shells.
Examination
Check the reliability of the gear fastening on the camshaft.
Check for wear on the bearing surfaces and cams, for oblique wear or non-flatness of the working surfaces.
Check the wear of the camshaft gear teeth.
Check the clearance of the toothed engagement of the crankshaft and toothed shaft gears. The clearance should be within 0.00-0.05 mm. The clearance can only be corrected by installing a new camshaft.
The camshaft is of the correct size if, when rotating it carefully in both directions, there is barely any play between the two gears when changing direction. The play is too small if, when rotating in the opposite direction, the camshaft lifts the crankshaft out of its bearings. If the play is too large, a camshaft of a different size group may be installed. To differentiate the sizes, numbers are stamped on the sides of the camshaft gears facing the cams. For example, -1, 0, +1, +2, etc. The number indicates how many hundredths of a millimeter the radius of the pitch circle of the gear differs from size group 0.
Note: The number "0" should not be confused with the letter "O", which is used to mark the timing gears. There is no marking for the crankshaft gears.
(The original material is available on the portal vwmanual.ru)
Installation
Different engines have different camshafts. Engine index DF: white; DG release up to 10.85; not painted; DG, SP issued since 11.85: green; MN, DJ: blue.
Before installation, the camshaft runout must be checked at a service station. The runout measured at the center of the camshaft can be a maximum of 0.04 mm.
The axial clearance of the camshaft should not exceed 0.16 mm.
If necessary, slightly remove the edges of the bearing seats.
Insert bearing shells 1-3 (counting from the flywheel side) in such a way that the projections enter the recesses in the engine crankcase, bearing 3, as a leading bearing, absorbs axial forces and therefore has a spacer lug on both sides for the camshaft.
Lubricate the bearing seats and camshaft cams with engine oil and insert the camshaft so that the gear tooth marked "0" is located between both marks on the crankshaft gear.
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