Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 679
– Bolt the Camshaft Lock - Component 2 - T40271/2- to the cyl‐
inder head and slide into the splines on the chain sprocket in
the direction of -arrow 2-. Rotate the intake camshaft with the
Adapter - T40266- -1- if necessary.
– Install the Camshaft Lock - Component 1 - T40271/1- on the
cylinder head.
For the following steps a second technician is necessity.
– Hold the exhaust camshaft with the Adapter - T40266- in the
direction of -arrow A-. Remove the bolt -1- and guide the ten‐
sioning rail -2- downward. Turn the camshaft further in a
clockwise direction -arrow A- until the Camshaft Lock - Com‐
ponent 1 - T40271/1- can be slid into the chain sprocket
splines in direction of -arrow B-.
– Check the installation position -arrow C- of the Camshaft Lock
- Component 1 - T40271/1- .
– Remove the guide rail -1- by unlocking the latch -arrow- with
a screwdriver and pushing the guide rail forward.
– Press the oil pump chain tensioner bracket in direction of
-arrow- and lock with Locking Pin (3 pc.) - T40011- .
– Remove the bolt -1- and remove the chain tensioner.
– Remove the bolts -1- and remove the glide rail -2-.
– Remove the camshaft timing chain from the camshaft bearing
and guide downward.
– Install the Assembly Tool - Turning Over Tool - T10531/3- . In
the “TDC point” the flat area -1- points upward. Install the As‐
sembly Tool - Knurled Nut - T10531/4- . Turn the crankshaft
with a 32 mm open end wrench counter-clockwise out of
“TDC”.
– Turn the intake camshaft in the direction of the -arrow 1- using
the Adapter - T40266- . Slide the Camshaft Lock - T40271/2-
-2- out of the chain sprocket splines and bring the camshaft
into the rest position.
– Turn the exhaust camshaft in the direction of the -arrow 1- us‐
ing the Adapter - T40266- . Slide the Camshaft Lock -
T40271/1- -2- out of the chain sprocket splines and bring the
camshaft into the rest position.
– Remove the cylinder head cover bolts -1 to 6- in sequence.
– Remove the cylinder head cover.
– Remove the camshaft and cover the open engine compo‐
nents.
Camshafts, Installing
Note
♦
Sealing surfaces must be completely free of oil and grease.
♦
Pay attention that all roller rocker levers rest on the valve stem
ends.
– If the crankshaft was turned in the meanwhile: bring the piston
for cylinder 1 to Top Dead Center (TDC) and then turn the
crankshaft back just a little.
– Remove any sealant residue from the groove on the cylinder
head cover as well as on the sealing surfaces.
– Clean the sealing surfaces. They must be free of oil and
grease.
– Lubricate the running surfaces of both camshafts.
– Place the intake camshaft -A- in the cylinder head. Turn the
cam lobes from cylinder 4 -arrows- upward.
– Check if the valve lifters for the cam adjustment actuators are
retracted.
– Place the exhaust camshaft in the cylinder head cover as il‐
lustrated. The cam pair -A and B- must be pushed together.
– Turn the exhaust camshaft until the markings -A and B- align.
– Apply the sealant on the clean sealing surface of the cylinder
head cover as illustrated -arrows-.
♦ Sealant bead thickness: 2 to 3 mm.
– Secure the camshaft and place the cylinder head cover with
the camshaft on the cylinder head.
– Lightly push on the cylinder head cover by hand and while
doing this turn the camshaft slightly until the cylinder head
cover lays free of tension on the cylinder head.
– Replace the cylinder head cover bolts.
– Tighten the bolts in several steps, tightening sequence. Refer
to
⇒ Fig. ““Cylinder Head Cover Tightening Sequence”“ ,
.
Note
Pay attention that the cylinder head cover is not tilted.
– Turn the intake camshaft with the Adapter - T40266- in the
direction of the -arrow A- until the markings -1 and 2- align.
Push the Camshaft Lock - Component 2 - T40271/2- in the
chain sprocket splines in direction of -arrow B-.
– Turn the exhaust camshaft with the Adapter - T40266- in the
direction of -arrow A- until the markings -1 and 2- align. Push
the Camshaft Lock - Component 1 - T40271/1- in the chain
sprocket splines -B-. The mark -2- is offset slightly to the right.
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