Pro
te
cte
d b
y c
op
yri
gh
t. C
op
yi
ng
fo
r p
riv
at
e
o
r c
o
m
m
e
rc
ia
l p
u
rp
o
s
e
s
, i
n
p
a
rt
o
r i
n
w
h
o
le
, i
s
n
o
t p
e
rm
itt
ed
u
nl
es
s a
ut
ho
ris
ed
by
Vo
lksw
agen
AG. Volkswagen AG doe
s not
gua
ran
tee
or a
cc
ep
t a
ny
lia
b
ilit
y w
ith
re
s
p
e
c
t t
o
th
e
c
o
rr
e
c
tn
e
s
s
o
f
in
fo
rm
a
tio
n
in
th
is
d
oc
um
en
t.
C
op
yrig
ht b
y V
olk
sw
age
n A
G.
– Tighten bearing caps 2 and 3 alternately and diagonally to 8
Nm + 90° (replace).
– Install bearing caps 1 and 4, and also tighten to 8 Nm + 90°
(replace).
Note
♦
Bearing cap 4 is identified as bearing cap 5.
♦
Apply Sealant -AMV 17400401- to seal surfaces of bearing
caps 1 and 4, which are in contact with the cylinder head
♦
Bearing cap 4 must align flush with outer edge of cylinder
head, because otherwise leaks may develop at the auxiliary
pump.
– Install the camshaft seal.
– Fit injector drive arm shaft and tighten first one bolt of each of
the inner pairs, then the other bolt of each pair, and finally the
outer securing bolts, evenly and alternately until there is no
more play in bearing, and finally tighten to torque. Tightening
torque: 20 Nm + 90° (replace).
– Install the hube on camshaft.
– Tighten hub fastening screw -1-. Tightening torque: 100 Nm.
– Use Blocking device -T10051- .
– Install camshaft gear on the hub.
Note
Toothed segment -arrow- of camshaft shall be on the top.
– Align camshaft gear in central position on elongated holes.
– Tighten manually the fastening screws -1- of the camshaft
gear in order not to have play.
– Immobilise hub with Mandrel -3359- .
– Install and adjust timing belt
⇒ page 41
.
– Install auxiliary pump
⇒ page 97
.
Note
When new tappets have been installed, do not start the engine
for about 30 minutes. Hydraulic compensation elements must knit
together (otherwise, valves will knock pistons).
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
60
Rep. Gr.15 - Cylinder head, valve control mechanism
