Volkswagen Golf/Jetta/Cabriole 1990-1999

Camshaft, Bearings and Lifters

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REMOVAL & INSTALLATION



8 Valve Engine


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Fig. Remove the nuts and washers noting their exact position



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Fig. Notice that some of the camshaft bearing caps have an integral nut/washer assembly



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Fig. Lift the bearing caps straight off the studs. Do not rock the caps side to side or the studs may bend



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Fig. Inspect the camshaft bearing caps for wear



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Fig. Lift the camshaft straight up once all the caps have been freed



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Fig. After all the caps have been removed and placed in their correct position on a marked sheet of paper, remove the camshaft

  1. Disconnect the negative battery cable. Remove the timing belt cover(s), the timing belt, cylinder head cover and the camshaft sprocket.
  2.  
  3. Number the bearing caps from front to back. If the cap does not already have one, scribe an arrow pointing towards the front of the engine. The caps are offset and must be installed correctly. Factory numbers on the caps are not always on the same side.
  4.  
  5. Remove the front and rear bearing caps. Loosen the remaining bearing cap nuts a little at a time to avoid bending the camshaft. Start from the outside caps near the ends of the head and work toward the center.
  6.  
  7. Remove the bearing caps and the camshaft.
  8.  

To install:



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Fig. Lubricate the hydraulic lifter. . .



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Fig. . . . then install it into the cylinder head



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Fig. Lifters reinstalled in the head in their correct positions

  1. Install a new oil seal and end plug in the cylinder head. Lubricate the camshaft bearing journals and lobes and set the camshaft in place.
  2.  
  3. Install the bearing caps in the correct position with the arrow pointing towards the front of the engine. Tighten the cap nuts diagonally and in several steps until they are torqued to 15 ft. lbs. (20 Nm). Do not over torque. Camshaft shaft endplay should be about 0.006 inches (0.15mm).
  4.  
  5. Install the drive sprocket and timing belt. Wait at least 1 / 2 an hour after installing camshaft shaft before starting the engine to allow the lifters to leak down.
  6.  

16v Engines
  1. Remove the timing belt cover.
  2.  
  3. Remove the upper intake manifold and cylinder head cover.
  4.  
  5. Turn the engine to TDC on cylinder No. 1, then slacken and remove the timing belt and camshaft sprocket.
  6.  
  7. With a felt marker only, matchmark the timing chain to the camshafts for reinstallation.
  8.  
  9. Remove the camshaft chain.
  10.  
  11. On the intake camshaft, remove bearing caps No. 5 and 7 and the chain end cap. Then loosen bearing caps No. 6 and 8 alternately and diagonally.
  12.  
  13. On the exhaust camshaft, remove bearing caps No. 1 and 3 and the end caps. Then loosen bearing caps No. 2 and 4 alternately and diagonally.
  14.  
  15. Remove the remaining bearing cap bolts and remove the camshafts.
  16.  

To install:

  1. Lubricate the camshaft bearing journals and lobes and set the camshafts in place. Install the camshaft drive chain so the marks on the chain sprockets are matched at the base of the cylinder head, directly across from each other.
  2.  


NOTE
When installing the bearing caps, make sure the notch points towards the intake side of the head.

  1. On the intake camshaft, install and torque bearing caps No. 6 and 8 alternately and diagonally to 11 ft. lbs. (15 Nm).
  2.  
  3. Install and torque the remaining intake camshaft bearing caps.
  4.  
  5. On the exhaust camshaft, torque bearing caps No. 2 and 4 alternately and diagonally to 11 ft. lbs. (15 Nm).
  6.  
  7. Install and torque the remaining exhaust camshaft bearing caps. Camshaft shaft end play on both camshafts should be about 0.006 inches (0.15mm).
  8.  
  9. Install the drive sprocket and timing belt.
  10.  
  11. Install remaining parts in reverse order of removal. Wait at least 1 / 2 hour after installing camshaft shafts before starting the engine to allow the hydraulic lifters to leak down.
  12.  

INSPECTION



Degrease the camshaft using a safe solvent. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable or a bearing journal scored, the camshaft should be replaced. Check the lobes and journals with a micrometer. Measure the lobes from nose to heel. If all intake or all exhaust lobes do not measure the same, replace the camshaft. If the lobes and journals appear intact, place the front and rear journals in V-blocks. Position a dial indicator on the center journal and rotate the camshaft. If deviation exceeds 0.01mm (0.0004 inches) replace the camshaft.

 
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