Volkswagen Golf Variant / Jetta. Manual - part 386

 

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Volkswagen Golf Variant / Jetta. Manual - part 386

 

 

⇒ Item 15 (page 291)

 and the press the charge air pipe slightly

downward to reach the rear threaded connection on the vac‐

uum pump.

– Remove the bolts -arrows-.
– Remove the vacuum pump -4- from the cylinder head.
Installing:
Install in reverse order of removal. Note the following:
• Make sure that vacuum pump coupling has proper seating in

camshaft.

• Always replace the vacuum pump seal.
• Make sure the line connections are secure.

– Install the vacuum pump -4- and tighten the bolts -arrows-.
• Tightening specification -item 8- 

⇒ Item 8 (page 85)

 .

– Tighten the charge air pipe bolts -item 15-

⇒ Item 15 (page 291)

 .

• Tightening specification -item 11- 

⇒ Item 11 (page 291)

 .

– Connect the brake booster vacuum hose -1- to the vacuum

pump.

– Install the air filter housing. Refer to

⇒ “3.14 Overview - Air Filter”, page 335

 .

– Install the engine cover. Refer to

⇒ “1.4 Engine Cover, Removing and Installing”, page 90

 .

1.9

Compression, Checking

Note

The compression can also be checking. Refer to Vehicle Diag‐

nostic Tester .

Special tools and workshop equipment required
♦ Compression Tester Kit - Adapter 12 - VAG1381/12-
♦ Compression Tester Kit - VAG1763-
Test Conditions
• Engine oil temperature must be at least 30 °C (86 °F).
• The battery voltage must be at least 12.7 V.
• All electrical consumers for example lamps and rear window

defogger, must be switched off.

Test Sequence
– Remove the glow plug from the applicable cylinder. Refer to

⇒ “1 Glow Plugs”, page 408

 .

– Install the Compression Tester Kit - Adapter 12 - VAG1381/12-

in place of the glow plugs.

– Check compression using the Compression Tester Kit -

VAG1763- .

1. Cylinder Head    

127

Refer to the Operating Instructions for information on using the

tester.

– Operate the starter until the Tester shows no further pressure

increase.

Compression Values:
• New: 25.0 to 31.0 bar (362.59 to 449.617 psi) pressure
• Wear limit: 19.0 bar (275.57 psi) pressure
• Permissible difference between all cylinders: maximum 5.0

bar (72.51 psi)

– Install the glow plug in the applicable cylinder. Refer to

⇒ “1 Glow Plugs”, page 408

 .

Note

By separating the connections, DTCs will be stored. After the test,

check the DTC memory and erase, if necessary.

– Check the DTC memory for the Engine Control Module - J623-

and erase all of the DTC entries. Refer to Vehicle Diagnostic

Tester in “Guided Functions”.

128

Valvetrain

⇒ “2.1 Overview - Valvetrain”, page 129
⇒ “2.2 Camshafts, Removing and Installing”, page 131
⇒ “2.3 Camshaft Seal, Removing and Installing”, page 137
⇒ “2.4 Valve Stem Seals with Cylinder Head Installed, Replacing”,

page 138
⇒ “2.5 Valve Guides, Checking”, page 141

Note

The plastic protectors installed to protect the open valves must

only be removed just before mounting the cylinder head.

When replacing the cylinder head or cylinder head gasket, the

coolant must be completely replaced.

Cylinder heads with cracks between the valve seats can con‐

tinue to be used without reducing service life, as long as the

tears have a width of maximum 0.5 mm.

Do not start the engine for approximately 30 minutes after in‐

stalling the camshafts. The hydraulic lifters must seat them‐

selves (otherwise the valves will crash into the pistons).

After working on the valvetrain and engine, carefully rotate by

hand at least two full turns to be sure that valves do not strike

pistons when starting.

Always replace the gaskets and seals.

2.1

Overview - Valvetrain

2. Valvetrain    

129

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❑ Do not coat the sealing

lip on the seal with oil or

grease

❑ Before installing, re‐

move the oil residue

from camshaft journal

with a clean cloth

❑ To install, tape over the

groove on the camshaft

cone.

❑ Removing and instal‐

ling. Refer to

⇒ “2.3 Camshaft Seal,

Removing and Instal‐

ling”, page 137

 .

2 - Bolt

❑ 10 Nm

3 - Nut

❑ 10 Nm

4 - Bearing Frame

❑ Observe the sequence

for loosening and tight‐

ening. Refer to

⇒ “2.2 Camshafts, Re‐

moving and Installing”,

page 131

 , Camshafts,

Removing and Installing

❑ Seal with Silicone Seal‐

ant - D 176 501 A1-

5 - Exhaust Camshaft

❑ Removing and instal‐

ling. Refer to

⇒ “2.2 Camshafts, Re‐

moving and Installing”,

page 131

 .

6 - Intake Camshaft

❑ Removing and installing. Refer to 

⇒ “2.2 Camshafts, Removing and Installing”, page 131

 .

7 - Roller Rocker Lever

❑ Mark the installed position
❑ Do not interchange
❑ Check the roller bearing for ease of movement
❑ Lubricate the running surfaces before installing

8 - Hydraulic Lifter

❑ Mark the installed position
❑ Do not interchange
❑ Lubricate the running surfaces before installing

9 - Valve

❑ Mark the installed position
❑ Do not rework, only lapping is permitted
❑ Valve Dimensions. Refer to 

⇒ Fig. ““Valve Dimensions”“ , page 131

 .

❑ Valve Guides, Checking. Refer to 

⇒ “2.5 Valve Guides, Checking”, page 141

 .

10 - Cylinder Head

❑ Observe the notes. Refer to 

⇒ page 129

 .

130

 

 

 

 

 

 

 

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