Removal
Remove valve cover. Place crankshaft at TDC. Remove ignition
coil. Remove double chain tensioner. Remove camshaft sprocket cover
with camshaft position sensor attached. Remove camshaft sprockets.
Mark timing chains for direction of rotation. If removing camshaft for
cylinders No. 1, 3 and 5, remove bearing caps No. 1 and 7 first, then
remove bearing caps No. 3 and 5. If removing camshaft for cylinders
No. 2, 4 and 6, remove bearing cap No. 4 first, then remove bearing
caps No. 2 and 6. Remove camshafts.
Inspection
Check camshaft bearing oil clearance. See CAMSHAFT table
under ENGINE SPECIFICATIONS. If oil clearance exceeds specification,
install new camshaft and recheck clearance. If clearance still exceeds
specification, replace cylinder head.
Installation
1) Lubricate all contact surfaces. When installing bearing
caps, ensure identification mark on bearing cap is readable from
exhaust manifold side and arrow points toward vibration damper. See
Fig. 14.
2) If installing camshaft for cylinders No. 1, 3 and 5,
tighten bearing caps No. 3 and 5 alternately in a diagonal sequence to
15 ft. lbs. (20 N.m). Repeat procedure for bearing caps No. 1 and 7.
3) If installing camshaft for cylinders No. 2, 4 and 6,
tighten bearing caps No. 2 and 6 alternately in a diagonal sequence to
15 ft. lbs. (20 N.m). Repeat procedure for bearing cap No. 4.
4) To complete installation, reverse removal procedure.
Ensure timing marks are properly aligned. If lifters are charged with
oil, allow 30 minutes for lifters to bleed down before starting
engine. Otherwise valves may come in contact with pistons.
Fig. 14: Installing Camshafts Into Cylinder Head
Courtesy of Volkswagen United States, Inc.
VALVE LIFTERS
Removal & Installation
Remove camshaft. See CAMSHAFT. Remove valve lifters from
cylinder head. Note position of each lifter. If lifters are reused,
they MUST be installed in original position. If replacement lifters
are charged with oil, allow 30 minutes for lifters to bleed down
before starting engine. Otherwise, valves may come in contact with
pistons. To complete installation, reverse removal procedure.
WATER PUMP
NOTE: Coolant/water mixture should be used at all times.
