Volkswagen Golf Variant / Jetta. Manual - part 388

secure the camshafts in the bearing frame.

– Remove the Cover - T40094/11- .
– Remove the Mount - T40094/8- from the groove in the intake

camshaft.

– Cut the tube nozzle at front marking (nozzle diameter: approx‐

imately 3 mm).

– Apply Silicone Sealant as shown on the clean cylinder head

sealing surface. The sealing compound bead must be:

• 2 to 3 mm thick
• Run around inside in the area of the bolt holes

Note

Sealant beads must not be thicker than 2 to 3 mm or else extra

sealant can enter camshaft bearing.

– Remove the camshafts together with the bearing frame and

the Camshaft Fitting Tool - T40095- from the Camshaft Fitting

Tool - T40094- .

– Carefully insert the camshafts and bearing frame in the cylin‐

der head.

2. Valvetrain    

135

sequence -1 to 24-.

• The guide frame must contact the entire contact surface of the

cylinder head.

– Tighten the bearing frame bolts or nuts in the sequence

-1 to 24-.

• Tightening specifications -item 2- 

⇒ Item 2 (page 130)

 and

-item 3- 

⇒ Item 3 (page 130)

 .

– Remove the Camshaft Fitting Tool - T40095- and the Grip

Jaws - T40096/1- .

– Replace the camshaft seal. Refer to

⇒ “2.3 Camshaft Seal, Removing and Installing”, page 137

 .

– Drive a new cap -item 15- 

⇒ Item 15 (page 131)

 onto the cyl‐

inder head with a suitable drift until it is flush.

The rest of the installation is performed in reverse order of re‐

moval, while doing so pay attention to the following:

Note

♦

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, carefully rotate engine by hand

at least two full revolutions to ensure that valves do not strike

the pistons when starting.

– Place the hub onto the camshaft.

– Counterhold the hub with the Counterhold - Camshaft Gear -

T10051- and tighten the hub bolt -1-.

• Tightening specifications. Refer to -item 11-

⇒ Item 11 (page 44)

 .

136

Note

The toothed segment -arrow- of the camshaft sprocket must face

upward.

– Install the bolts -1- into the camshaft sprocket by hand without

play.

– Lock the hub with the Diesel Injection Pump Locking Pin -

3359- .

– Installing and tensioning the toothed belt. Refer to

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

page 95

 .

– Install the vacuum pump. Refer to

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

 .

– Install the cylinder head cover. Refer to

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

page 90

 .

2.3

Camshaft Seal, Removing and Installing

Special tools and workshop equipment required
♦ Seal Installer - Crankshaft/Camshaft - 10-203-
♦ Puller - Camshaft Seal - 3240-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ M12x65 bolt
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 camshaft sprocket and the hub. Refer to

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

 , Cam‐

shafts, Removing and installing.

– Insert the Puller - Camshaft Seal Supplement -3240/1- into the

camshaft.

– Remove the inner section of the Puller - Camshaft Seal - 3240-

two rotations (approximately 3 mm) from the outer section and

secure with a knurled bolt.

2. Valvetrain    

137

3240- position it and install it as far as possible into the seal

using force.

– Loosen the knurled bolt and turn inner section against cam‐

shaft until the seal is removed.

Installing:

Note

The sealing lip of the seal may not be additionally oiled or

greased.

– Clean off any oil residue on the camshaft pin with a clean cloth.

– Mount the guide sleeve from the Puller - Camshaft Seal - 3240-

on the camshaft as shown.

– Carefully slide the shaft seal -1- over the guide sleeve and onto

the camshaft.

– Press the seal in the thrust piece from the Seal Installer -

Crankshaft/Camshaft - 10-203- and install the M12x65 bolt all

the way.

– Install the camshaft sprocket and the hub. Refer to

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

 , Cam‐

shafts, Removing and installing.

– Installing and tensioning the toothed belt. Refer to

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

page 95

 .

2.4

Valve Stem Seals with Cylinder Head

Installed, Replacing

Special tools and workshop equipment required
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem - 3365-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Valve Keeper Tool Kit - VAS5161A-
Removing:
– Remove all the glow plugs. Refer to

⇒ “1 Glow Plugs”, page 408

 .

– Remove the camshafts. Refer to

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

 .

138