Camshaft, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Remove upper toothed belt guard, cylinder head cover and vacuum pump.

Fig 1: Identifying TDC For Cylinder 1 (Manual Transmission)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft to TDC for cylinder 1 (on vehicles with manual transmission). B: For engine code ALH

Fig 2: Identifying Crankshaft At TDC No. 1 Cylinder (Automatic Transmission)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft to TDC for cylinder 1 - arrow - (with automatic transmission).

Fig 3: Identifying Camshaft Secured Using Adjustment Guide 3418

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure camshaft using adjustment guide 3418.
Align adjustment guide as follows: Turn secured camshaft until the end of the adjustment guide is seated against cylinder head. On other end of adjustment guide, measure the resulting clearance with feeler gauges. Insert a feeler gauge, with half of the clearance dimension, between adjustment guide and cylinder head. Turn camshaft until the adjustment guide is seated against the feeler gauge. Insert a second feeler gauge with same dimension at other end between adjustment guide and cylinder head.

NOTE:

Camshaft can also be secured using camshaft bar T10098.

Fig 4: Identifying Injection Pump Sprocket, Rig Pin 3359, Bolts & Nut

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lock injection pump sprocket with rig pin 3359.
Loosen tension roller.
Remove toothed belt.
Loosen camshaft sprocket bolt by one revolution. To loosen bolt, counterhold camshaft sprocket using counter-holder 3036.

NOTE:

When loosening and tightening the camshaft sprocket, never use the camshaft bar T10098 or adjustment guide T10098 to counter-hold! Use the counter-holder 3036.

Fig 5: Identifying Puller T40001 With The One-Armed Claw T40001/2 & Two-Armed Claw T40001/3, Camshaft Sprocket & Open-End Wrench

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set puller T40001 with one-armed claw T40001/2 - A - and two-armed claw T40001/3 - B - center onto camshaft sprocket and pull it off. To counter-hold, use an open-end wrench - C -.
Remove camshaft sprocket.
First remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally and remove.