Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 681

 

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Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 681

 

 

Note

Tighten the bolts -1 and 4- with an additional turn after installing

the vibration damper. The bolts must be removed again to install

the vibration damper.

– Install the vibration damper. Refer to

⇒ “1.4 Vibration Damper, Removing and Installing”, page 47

 .

– Install the upper timing chain cover. Refer to

⇒ “2.2.1 Upper Timing Chain Cover, Removing and Installing”,

page 106

 .

– Install the ribbed belt tensioning damper. Refer to

⇒ “1.3 Ribbed Belt Tensioner, Removing and Installing”, page

47

 .

– Install the ribbed belt. Refer to

⇒ “1.2 Ribbed Belt, Removing and Installing”, page 46

 .

– Install the vacuum pump. Refer to

⇒ “1.4 Vacuum Pump, Removing and Installing”, page 100

 .

– Install the high pressure pump. Refer to

⇒ “7.2 High Pressure Pump, Removing and Installing”,

page 328

 .

The rest of the installation is performed in reverse order of re‐

moval, noting the following:
– After performing work on the chain drive the adaptation value

in the Engine Control Module (ECM) must be adapted. To do

this turn on the ignition and select the following menu items on

the Vehicle Diagnostic Tester :

01 - Engine Electronics

Guided Functions

01 - Adaptation After Repair Work on the Chain

Drive

Tightening Specifications
♦ Refer to

⇒ “3.1 Overview - Camshaft Timing Chain”, page 114

 .

♦ Refer to

⇒ “3.2 Overview - Balance Shaft Drive Chain”, page 116

 .

♦ Refer to 

⇒ “4.1 Overview - Valvetrain”, page 133

 .

♦ Refer to 

⇒ “3.1 Overview - Air Filter Housing”, page 293

 .

♦ Refer to 

⇒ “7.1 Overview - High Pressure Pump”, page 325

 .

♦ Refer to ⇒  Body Exterior; Rep. Gr.  66 ; Noise Insulation;

Overview - Noise Insulation .

4.3

Camshaft Adjustment Valve 1 - N205- ,

Removing and Installing

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Bolts - Camshaft Adjustment Valve 1
♦ O-ring - Camshaft Adjustment Valve 1
♦ Seal - Camshaft Adjustment Valve 1
Removing
– Remove the engine cover. Refer to

⇒ “3.1 Engine Cover, Removing and Installing”, page 38

 .

– Unclip the coolant and fuel lines and set them aside.
– Disconnect the connector -1- from the Camshaft Adjustment

Valve 1 - N205- .

– Remove the bolts -arrows- and then the Camshaft Adjustment

Valve 1 - N205- -2-.

Installing
Install in reverse order of removal. Note the following:

Note

Replace seals and O-rings.

– Lubricate seals on the Camshaft Adjustment Valve 1 - N205- /

Exhaust Camshaft Adjustment Valve 1 - N318- sealing surfa‐

ces with engine oil.

Tightening Specifications
♦ Refer to 

⇒ “2.1 Overview - Timing Chain Cover”, page 104

 .

4.4

Camshaft Adjustment Valve 1 - N205-

and Exhaust Camshaft Adjustment

Valve 1 - N318- , Removing and Instal‐

ling

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Bolts - Camshaft Adjustment Valve 1
♦ O-ring - Camshaft Adjustment Valve 1
♦ Seal - Camshaft Adjustment Valve 1
♦ Bolts - Exhaust Camshaft Adjustment Valve 1
♦ O-ring - Exhaust Camshaft Adjustment Valve 1
♦ Seal - Exhaust Adjustment Valve 1
Removing
– Remove connector -1- from Exhaust Camshaft Adjustment

Valve 1 - N318- and connector -3- from Camshaft Adjustment

Valve 1 - N205- .

– Remove the bolts -arrows- and Camshaft Adjustment Valve 1

- N205- -4- and Exhaust Camshaft Adjustment Valve 1 - N318-

-2-.

Installing
Install in reverse order of removal. Note the following:

Note

Replace seals and O-rings.

– Lubricate seals on the Camshaft Adjustment Valve 1 - N205- /

Exhaust Camshaft Adjustment Valve 1 - N318- sealing surfa‐

ces with engine oil.

Tightening Specifications
♦ Refer to 

⇒ “2.1 Overview - Timing Chain Cover”, page 104

 .

4.5

Sliding Bar Ball, Installing

Special tools and workshop equipment required
♦ Camshaft Spacer - T40191-
Installing

CAUTION

Risk of injuring the eyes due to the sliding ball bar springing out.
– Wear protective eyewear.

– Insert the spring -1- in the camshaft.
– Place the ball -2- on the spring in the camshaft.
– Push the ball and spring downward in direction of -arrow A-

using the Camshaft Spacer - T40191/1- and hold.

– Push the sliding bar -3- in the direction of -arrow B-.

4.6

Valve Stem Seals, Removing and In‐

stalling

⇒ “4.6.1 Valve Stem Seals, Removing and Installing, Cylinder

Head Installed”, page 163

 .

⇒ “4.6.2 Valve Shaft Seals, Removing and Installing, Cylinder

Removed”, page 166

 .

4.6.1

Valve Stem Seals, Removing and In‐

stalling, Cylinder Head Installed

Special tools and workshop equipment required
♦ Spark Plug Removal Tool - 3122B-
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem - 3365-
♦ Valve Cotter Tool Kit - Adapter - T40012-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Valve Keeper Tool Kit - VAS5161A-
♦ Valve Cotter Tool Kit - Guide Plate 19B - VAS5161/19B-
♦ Valve Cotter Tool Kit Knurled Thumb Screws M6 -

VAS5161/12-

♦ Punch - VAS5161/3A-
Remove Valve Stem Seals
– Remove the camshafts. Refer to

⇒ “4.2 Camshaft, Removing and Installing”, page 136

 .

– Mark the allocation of the roller rocker lever and the hydraulic

adjusting elements so they can be installed again.

– If necessary, remove the roller rocker levers with the hydraulic

adjusting elements and place them on a clean surface.

– Remove the spark plugs using a Spark Plug Removal Tool -

3122B- .

– Install the Valve Cotter Tool Kit - Guide Plate 19B -

VAS5161/19B- with the Valve Cotter Tool Kit Knurled Thumb

Screws M6 - VAS5161/12- as shown on the cylinder head.

– Move piston for that cylinder to “bottom dead center position”.

 

 

 

 

 

 

 

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