Volkswagen Golf / Golf Plus. Manual - part 311

 

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Volkswagen Golf / Golf Plus. Manual - part 311

 

 

Note

When camshaft is installed, No. 1 cylinder cams must point

upwards.

Do not interchange used bearing shells (mark).

When installing the camshaft, ensure proper seating of retain‐

ing lugs in bearing caps and cylinder head.

Before installing bearing caps, ensure that cylinder head bolt

washers are inserted in the cylinder head.

– Oil bearing shell running surfaces.
– Install bearing caps 2 and 4 using new bolts.
– Tighten bearing caps 2 and 4 diagonally and alternately to

8 Nm + 

1

/4 turn (90°).

– Install bearing caps 5, 1 and 3 using new bolts.

Note

Seal parting surfaces of bearing caps 1 and 5 with sealant -

AMV 174 004 01- 

⇒ page 76

 .

Bearing cap 5 must align flush with outer edge of cylinder

head, because otherwise leaks can develop at tandem pump.

– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm +

1

/4 turn

(90°).

– Install camshaft oil seal. 

⇒ page 84

– Install rocker arm shafts and tighten securing bolts, first the

inner -2- and then the outer -1-, evenly and diagonally to 20 Nm

1

/4 turn (90°).

– Fit hub onto camshaft.

– Tighten hub securing bolt -1- to 100 Nm.
– To do this, use counterhold tool -T10051- .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

82

     Rep. Gr.15 - Cylinder head, valve gear

 

The toothed segment -arrow- of the camshaft toothed belt pulley

must be on top.

– Align camshaft toothed belt pulley at centre of elongated

holes.

– Hand tighten securing bolts -1- to camshaft toothed belt pulley

so that there is no play.

– Lock hub using locking pin -3359- .
– Install and tighten toothed belt 

⇒ page 50

 .

– Screw new adjustment screws into rocker arms hand-tight and

fit lock nut.

– Fit the dial gauge onto the adjustment screw of the unit injector

as shown.

– Turn crankshaft in direction of engine rotation until roller of

rocker arm is located at tip of drive cam. Roller side

-arrow A- is positioned at highest point and dial gauge

-arrow B- is positioned at lowest point.

– Remove dial gauge.
– Now turn the adjuster screw into rocker arm until significant

resistance can be felt (unit injector is at limit stop).

– Turn adjustment screw 180° back off stop.
– Hold adjuster screw in this position and tighten lock nut to 30

Nm.

– Install tandem pump 

⇒ page 147

 .

– Install cylinder head cover.

Note

When new tappets have been installed the engine must not be

started for about 30 minutes, hydraulic compensation elements

must settle (otherwise valves will strike pistons).

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2. Valve gear    

83

 

Special tools and workshop

equipment required
♦ Fitting sleeves -10-203-
♦ Oil seal extractor -3240-
♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1332-

♦ Bolt M12×1.5 × 65

2.5.1

Removing

– Remove toothed belt. 

⇒ page 50

– Remove camshaft toothed belt pulley and hub 

⇒ page 80

 ,

Removing and installing camshaft.

– Unscrew inner part of oil seal extractor -3240- two turns (ap‐

prox. 3 mm) out of outer part and lock with knurled screw.

– Lubricate threaded head of oil seal extractor -3240- , place it

in position and exerting firm pressure, screw it as far as pos‐

sible into oil seal.

– Loosen knurled screw and turn inner part against camshaft

until oil seal is pulled out.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

84

     Rep. Gr.15 - Cylinder head, valve gear

 

Note

The oil seal sealing lip must not be additionally oiled or greased.

– Remove oil residue from camshaft journal using a clean cloth.
– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool -10-203- and

bolt M12 5x65 onto stop.

– Install and tighten toothed belt 

⇒ page 50

 .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2. Valve gear    

85

 

 

 

 

 

 

 

 

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