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”“ ,

page 135

 .

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.