Dismantling
Remove air filter. Remove the top toothed belt cover.
5-cylinder engine: remove the upper part of the intake manifold.
Remove cylinder head cover.
Set the crankshaft to TDC on the 1st cylinder.
Attention: Do not change the position of the motor any more.
Loosen the toothed belt and remove it upwards from the camshaft wheel.
5-cylinder engine: remove the ignition distributor.
Secure the camshaft gear at the front with a suitable pin. Unscrew and remove the camshaft gear, otherwise knock it out with light blows from a rubber mallet. Remove the camshaft key.
Mark all bearing caps.
Remove the 1st and 3rd bearing caps. Then loosen the 2nd and 4th alternately crosswise.
Diesel engine: First remove bearing caps 5, 1 and 3, then loosen bearing caps 2 and 4 alternately crosswise.
Take out the distributor.
Attention: If poppets are removed, they must be replaced so that they can then be restored to their original position. Lay the pushers on the working surface (camshaft side) down.
Installation
The camshaft is marked with numbers and letters stamped between the intake and exhaust cams.
Attention: For 4-cylinder petrol engines, the cylinder heads are partially supplied with bearing shells. There are two versions here: Cylinder head with machined journals to use a normal sized camshaft (neck diameter = 26.00).
Attention: Cylinder head with machined bushings and camshaft with reduced main journals (neck size = 25.75 mm and a yellow dot on the VW-AUDI sign). The latter camshafts are not available as spare parts, a normal size camshaft with appropriate bearing shells should be used.
Before installing a long life camshaft, it must be checked for radial damage. Its allowable value is 0.01 mm.
If a camshaft with a long service life is installed or if there is noise in the operation of the gas distribution mechanism, it is necessary to check the axial (longitudinal) gap. Its allowable value is 0.15 mm. The measurement takes place with the poppets removed and the 1st and 4th bearing caps installed, for the diesel engine the 1st and 5th.
Install a new camshaft seal. Lubricate the mounting points lightly.
If the back plug is damaged, replace it.
Install bearing caps. Check the absence of their lateral displacement. The holes in the covers and the cylinder head must match.
If the poppets have been removed, they must be reinstalled. Lubricate the tappets lightly and insert into place without distortion.
Attention: Poppet pushers are not replaceable.
Lubricate and install the camshaft.
Attention: The cams of the 1st cylinder must point upwards. Install the bearing caps according to the marks. Monitor axial displacement; Tighten bearing caps 2 and 4 alternately crosswise to 20 Nm.
Install bearing caps 1 and 3 and tighten to 20 Nm.
Diesel engine: Install bearing caps 5, 1 and 3 and tighten to 20 Nm. In this case, adjust the bearing cover 5 with light blows of a polymer hammer.
Insert the camshaft gear key. Fit the gear and tighten to 80 Nm. While doing this, hold the pinion with a suitable pin.
Place toothed belt on gear. Make sure that the intermediate shaft and V-belt pulley are correctly installed.
Pull on toothed belt.
Use a new seal for the cylinder head cover, carefully tighten the cylinder head cover bolts to 10 Nm.
5 cylinder engine.
Install the ignition distributor.
Install the intake manifold top.
Install the toothed belt cover.
Install the air filter.
Attention: if new poppets have been installed, the engine must not be started for about 30 minutes, otherwise the valves may collide with the pistons.
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