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