Camshafts and hydraulic chain tensioner, removing and installing: Installing

Fig 1: Sealant Application Area Identified By Hatched Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace rubber/metal gasket for hydraulic chain tensioner and apply a thin coat of sealant "D 454 300 A2" to the shaded area.
Install drive chain on camshaft sprockets as follows:

Fig 2: Installing Chain So That Colored Markings Are In Line

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When the old chain is being re-installed, install the chain so that the colored markings are in line (arrows).

Fig 3: First And Sixteenth Drive Chain Rollers Installed On Chain Gears

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When a new chain is being installed, the distance between the notches -A- and -B- on the camshafts must be 16 rollers on the chain. The illustration shows the exact positions of the 1st and 16th rollers on the sprockets.
Notch -A- is offset slightly toward the inside in relation to chain roller -1-.

Insert hydraulic chain tensioner into the chain.
Locate camshafts together with chain and hydraulic chain tensioner on cylinder head.
Oil running surfaces of both camshafts.

NOTE:

Dowel sleeves for bearing caps and hydraulic chain tensioner must be located in cylinder head.
When installing bearing caps ensure that the identification mark is readable from the intake side of cylinder head.

Fig 4: Identifying Bearing Cap Positions

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Tighten bearing caps 2 and 4 of intake and exhaust camshafts in stages and in diagonal sequence (watch position of dowel sleeves).
Install the two bearing caps next to the chain sprockets on the intake and exhaust camshafts.
Check correct setting of camshafts:

Fig 5: Positioning Camshafts To TDC Cyl. 3

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The two markings on the camshafts must be in line with the two arrows on the bearing caps (arrows).

Fig 6: First And Sixteenth Drive Chain Rollers Installed On Chain Gears

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The distance between the two arrows on the bearing caps (or between the colored markings) is 16 rollers on the chain.
The notch on the exhaust camshaft is offset slightly toward the inside in relation to chain roller -1-.

Fig 7: Identifying Double Bearing Cap Sealant Application Area

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Apply a thin coat of sealant "D 454 300 A2" to shaded area on double bearing cap and install bearing cap (watch position of dowel sleeves).

Install remaining bearing caps (watch position of dowel sleeves).
Install new intake and exhaust camshaft oil seals. Refer to Camshaft oil seals, replacing .

Fig 8: Identifying Camshaft Gear Thin Rib Toward Outside And TDC Marking Visible

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Check installation position: The narrow web of the camshaft sprocket faces outward (arrows) and the marking for No.1 cylinder TDC is visible from the front.

Fig 9: Setting Crankshaft To Markings For TDC Of No. 1 Cylinder

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Align camshaft sprocket mark with marking on cylinder head cover.
Align marking on vibration damper with marking on lower part of toothed belt guard.

NOTE: The crankshaft must not be at TDC when the camshaft is rotated, otherwise valves can contact pistons and cause damage.

Install toothed belt (adjust valve timing). Refer to Installing (adjusting valve timing) .
Install ribbed belt and ribbed belt tensioning element. Refer to Installing ribbed belt .

NOTE:

Follow all instructions for removing and installing toothed belt. Refer to Toothed belt, removing and installing .
Wait about 30 minutes after installing the camshafts before starting the engine. The hydraulic valve compensating elements must settle (otherwise the valves will strike the pistons).
After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.