Volkswagen Golf Variant / Jetta. Manual - part 388

 

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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

 

 

 

 

 

 

 

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