Volkswagen Golf/Jetta 2 manual

Camshafts - removal and refitting
Engine repair procedures 1.8 litre 16 valve / Camshafts - removal and refitting


Removal
1 Remove the camshaft sprocket cover.

2 Unbolt and remove the upper section of inlet manifold.

3 Unbolt and remove the valve cover after disconnecting the HT leads from the spark plugs. Remove the main gasket and the central gasket from around the spark plug locations.

4 Align the timing marks with reference to Part C of this Chapter, then check also that the marks on the chain sprockets are aligned (see illustration).

3.4 TDC timing marks in alignment on camshaft drive chain sprockets
3.4 TDC timing marks in alignment on camshaft drive chain sprockets

5 Remove the timing belt and camshaft sprocket with reference to Part C of this Chapter.

6 Note the fitted positions of the camshaft bearing caps, if necessary marking them to ensure correct refitting (see illustration).

3.6 Camshaft bearing cap identification
3.6 Camshaft bearing cap identification

Inset shows recessed corner position (arrowed)

7 Progressively unscrew the nuts and bolts from the end caps and bearing cap Nos. 1 and 3 on the exhaust camshaft.

8 Progressively unscrew the bolts from bearing cap Nos. 2 and 4. The exhaust valve springs will force the exhaust camshaft up as the bolts are loosened. Remove the bearing caps keeping them identified for position.

9 Working on the inlet camshaft, progressively unscrew the nuts and bolts from the end cap and bearing cap Nos. 5 and 7.

10 Progressively unscrew the bolts from bearing cap Nos. 6 and 8, then remove all the caps keeping them identified for position.

11 Lift both camshafts from the cylinder head then release them from the drive chain.

12 If necessary, remove the hydraulic bucket tappets. Check the camshafts and drive chain for wear.

Refitting
13 Lubricate all bucket tappets and camshaft journals with clean engine oil, then insert the tappets in their original bores.

14 Locate the drive chain on the camshaft sprockets so that the timing marks are aligned as shown in illustration 3.4, then lower the camshafts into position on the cylinder head.

Recheck the timing mark alignment.

15 Fit a new oil seal to the front end of the exhaust camshaft.

16 When refitting the bearing caps, make sure that they are located the correct way round. The numbers must be readable from the inlet manifold side of the head. The recessed corners of the caps must also face the inlet manifold side of the head.

17 Refit bearing cap Nos. 6 and 8, then progressively tighten the bolts to the specified torque.

18 Refit the inlet camshaft end cap and bearing cap Nos. 5 and 7, then progressively tighten the nuts and bolts to the specified torque.

19 Refit bearing cap Nos. 2 and 4, then progressively tighten the bolts to the specified torque.

20 Refit the exhaust camshaft end caps and bearing cap Nos. 1 and 3, then progressively tighten the nuts and bolts to the specified torque.

21 Refit the camshaft sprocket and timing belt with reference to Part C of this Chapter and Section 2.

22 Check that all timing marks, including the drive chain sprocket marks, are aligned.

23 Refit the valve cover together with new gaskets and reconnect the spark plug HT leads.

24 Refit the inlet manifold upper section and the camshaft sprocket cover.


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