Volkswagen Golf Variant / Jetta. Manual - part 387

 

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Volkswagen Golf Variant / Jetta. Manual - part 387

 

 

⇒ Fig. ““Cylinder Head, Checking for Distortion”“ , page 86

 .

❑ Removing and installing. Refer to 

⇒ “1.7 Cylinder Head, Removing and Installing”, page 103

 .

❑ All of the coolant must be replaced after installing

11 - Valve Stem Seal
Replacing. Refer to 

⇒ “2.4 Valve Stem Seals with Cylinder Head Installed, Replacing”, page 138

 .

12 - Valve Spring
13 - Valve Spring Retainer
14 - Cone Piece
15 - Cap

❑ Replace
❑ Drive in flush using a suitable drift

Valve Dimensions

Note

Intake and exhaust valves must not be reworked. Only lapping is

permitted.

Dimension

Intake Valve

Exhaust Valve

Diameter

a

mm

26.60

26.00

Diameter

b

mm

5.940

5.940

c

mm

99.30

99.10

α

∠°

45

45

2.2

Camshafts, Removing and Installing

Special tools and workshop equipment required
♦ Diesel Injection Pump Locking Pin - 3359-
♦ Counterhold - Camshaft Gear - T10051-
♦ Puller - Camshaft Sprocket - T10052-
♦ Camshaft Fitting Tool - T40094A-
♦ Camshaft Fitting Tool - T40095-
♦ Camshaft Fitting Tool - T40096 - T40096-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Hand Drill with Plastic Brush Attachment
♦ Protective Eyewear
♦ Silicone Sealant - D 176 501 A1-

2. Valvetrain    

131

 .

Removing
– Remove the toothed belt from the camshaft and the high pres‐

sure fuel pump. Refer to

⇒ “1.6 Toothed Belt, Removing, Installing and Tensioning”,

page 95

 , Toothed Belt, Removing, Installing and Tensioning.

– Remove the cylinder head cover. Refer to

⇒ “1.5 Cylinder Head Cover, Removing and Installing”,

page 90

 .

– Remove the bolts -1- for camshaft sprocket.
– Remove the camshaft sprocket from the hub.

– Counterhold the hub with the Counterhold - Camshaft Gear -

T10051- and loosen the hub bolt -1-.

– Unscrew the bolt for the hub by approximately two turns.

– Mount the Puller - Camshaft Sprocket - T10052- and align the

Puller - Camshaft Sprocket to the holes in the hub.

– Tighten the bolts -1-.
– Tighten the Puller -2- evenly to tension the hub until the hub

loosens from the camshaft cone.

Note

Hold the Puller at the same time with a 30 mm wrench.

– Remove the hub from the camshaft cone.
– Remove the vacuum pump. Refer to

⇒ “1.8 Vacuum Pump, Removing and Installing”, page 126

 .

132

-24 to 1-.

– Remove the bearing frame.
– Carefully remove the camshafts.
Installing:

Note

Note the expiration date for the Sealant .

Seal the separating surface between the bearing frame and

the cylinder head with Silicone Sealant - D 176 501 A1- .

Caution

♦ The camshafts may only be installed using the Camshaft

Fitting Tool - T40094- as described below. Otherwise the

axial bearing in the bearing frame will be destroyed and

the cylinder head will have to be replaced.

♦ Make sure that no sealant residue enters the cylinder head

or the bearings.

WARNING

Wear protective eyewear.

– Remove any sealant residue from the cylinder head and on

the bearing frame using, for example, a rotating plastic brush.

– Clean the sealing surfaces, they must be free of oil and grease.
– Oil the contact surfaces of the camshafts.
Assemble the Camshaft Fitting Tool - T40094- as follows:

– Remove the Camshaft Fitting Tool - Mounts - T40094/3- , -

T40094/4- and - T40094/5- from the base plate. Loosen the

threaded connections from below.

Note

If the Camshaft Fitting Tool - T40094A- mounts are not marked,

mark the removed mounts, for example, with numbers, to assure

it can be assembled later.

2. Valvetrain    

133

and - T40094/10- in the empty outer locations.

– Place the Camshaft Fitting Tool - Mount - T40094/2- at position

“A” and Camshaft Fitting Tool - Mount - T40094/1- at position

“F”.

– First install the intake camshaft as shown. Make sure the re‐

cess -arrow- for the cylinder head bolt faces »outward«.

– Install a 0.50 mm feeler gauge and push the Camshaft Fitting

Tool - Mount - T40094/8- into the groove on the intake cam‐

shaft.

– Now insert the exhaust camshaft.

– Secure the exhaust camshaft above its groove -arrow- using

the Camshaft Fitting Tool - Cover - T40094/11- .

– Mount the Grip Jaws - T40096/1- on the exhaust camshaft

gears.

Caution

Make sure the clamping bracket marked with an arrow is on

the wider sprocket.

– Tighten the Grip Jaws - T40096/1- with the thumbwheel until

the tooth flanks align. If necessary use a 13 mm open end

wrench.

– Slide the intake camshaft toward the exhaust camshaft until

the splines are engaged.

– Position the bearing frame on the camshafts.
• All the camshaft bearings must lie on the camshafts.

134

 

 

 

 

 

 

 

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