Genuine Volkswagen Golf SportWagen Cam Gear

Volkswagen Golf SportWagen Cam Gear Parts and Q&A

• Actuator
  04E-109-088-AE
  Q: What precautions should be taken when disconnecting the battery and Cam Gear, Camshaft and Rocker Arm for 4-cylinder engines on Volkswagen Golf SportWagen?

  A:

  When the battery has been disconnected, a number of systems will need to be re-learned until they start operating correctly. In case of mistakes, the engine will suffer serious damages; the process should not be performed by an untrained person in this kind of repair. In case uncertain of capabilities, seek advice of someone with knowledge and ensure that all work is completed before one tries to start the engine. Interim inspection of camshafts and lifters must be done before fitting, and prior to withdrawal of camshafts, endplay inspection must be done. The camshafts may not be pulled out of the camshaft housing on 1.4L (CZTA, DGXA) models, and in the situation of an issue, the camshafts and housing have to be replaced together. Untether the cable on the negative terminal of the battery, empty the cooling system, pull out air filter housing, resonator, take out the water pump, ignition coils, high-pressure fuel pump, and disconnect the electrical connector on different sensors. Disassemble the turbocharger coolant pipes, fasteners of the heat shield, upper cover of the timing belt, and position the engine at TDC. The camshaft housing bolts should be loosened in the reversal order in which they were tightened, and the camshaft housing should then be carefully removed in relation to the cylinder head, and all remnants of the gasket sealing compound removed. Cylinder head Mark and remove the roller rocker and lifters as they occur in the cylinder head, making sure that they are re-inserted in their respective positions. In the case of camshaft sprockets, special tools should be used so as not to turn when loosening bolts and installation of new seals should also be done so as to maintain cleanliness. Installation On 2.0L (CBPA) models, proceed the same way, but make sure to align and fit correctly and to use the appropriate torque specification. In 1.8L and 2.0L timing chain models, the camshaft bearings should not be machined, but should be incorporated and have to be followed through the removal and installation steps with care, checking all the marks and alignments. Refilling the cooling system, clean and lubricate all parts, and install in the right sequence and leakage.
• Actuator
  04E-109-088-AD
  Q: What precautions should be taken regarding Cam Gear and Timing Belt during the replacement procedure on Volkswagen Golf SportWagen?

  A:

  This procedure should be done with caution because the rotating of crankshaft or the Camshaft alone with the timing belt released may damage the valves, a minimum of rotation of the camshaft is only necessary to make sure that the marks of the sprockets match with the rear timing belt cover. The battery has to be disconnected by re-educating oneself on a number of systems to work with. This is a procedure that can be used on the 2.0L (CBPA) and 1.4L (CZTA, DGXA) engines. The complexity of the timing system requires a lot of experience; any error may cause serious damage to the engine, and it is better to use the services of a specialist in this case. See that contact points of timing belt components are not oiled to ensure they do not fail prematurely. Start by unscrewing the negative battery cable, unscrewing the wheel bolts on the right-front, lifting the vehicle high enough, and removing the right-front wheel. Take off the splash shield, inner fender liner on the driver side and label the direction of rotation of the drive belt and remove it together with the spark plugs. Once the locking pin of tensioner is removed, place the engine at TDC position and take off coolant expansion tank, air filter housing, turbocharger pipes, and disconnection fittings of fuel hose. Detach retaining clips, upper timing belt cover, crankshaft pulley and lower cover fasteners. When using a timing belt again, indicate its direction of movement. Its timing belt is easily removed by lifting the tensioner but not bending it sharply. With the 2.0L, make certain that the crankshaft is at TDC, hold the engine and lift off the passenger side Engine Mount and bracket. A wrench is used to avoid crankshaft rotation when loosening the retaining bolts of the pulley. Check the tensioner pulley and idler wheel on the timing belt to ensure it works properly and examines the belt to confirm that it is not contaminated or worn out. In case of a good belt, it should be fitted back in the same position. Change the belt in case of concern about the state of it or possibility of a surpass of 60,000 miles. Prior to fueling the engine, turn the crankshaft by hand to confirm resistance that is an indication of a problem. On the 1.4L engines, be sure the crankshaft is set at TDC, replace any components removed and make sure the timing belt runs correctly around the sprockets noting rotation marks. With the 2.0L engines, make sure that the mark of the camshaft sprocket is properly aligned, loop the timing belt, and also ensure that all the timing marks are at TDC. Tension the belt, and verify that everything is in line after two full revolutions of the crankshaft, and it is important to note that the procedure should be reversed in order to reassemble.