Camshaft oil seals, replacing

Replacing exhaust camshaft oil seal

Removing

Remove noise insulation in center and on right-hand side.
Removing ribbed belt and tensioning element. Refer to Ribbed belt, removing and installing .
Remove upper toothed belt guard. Refer to Toothed belt, removing and installing .

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

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Set crankshaft to markings for TDC of No. 1 cylinder -arrows- by turning central bolt on crankshaft sprocket in direction of rotation.
Disconnect vacuum hose from activated charcoal filter and from throttle valve connection.
Unbolt coolant expansion tank and power steering reservoir, but do not disconnect the hoses.

Fig 2: Screwing Stud Into Toothed Belt Tensioning Element & Hex Nut Onto Stud Using Large Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Screw M5x55 stud -1- into toothed belt tensioning element. Screw hex nut -2- with a large washer -3- onto stud -1-.
Tension pressure piston of tensioning element just enough so that it can be secured with a suitable locking pin (e.g. from lifting appliance 2024 A).

NOTE: If it is not possible to insert the locking pin, carefully tension the pressure piston of the tensioning element just enough to allow the toothed belt to be removed.

Take toothed belt off camshaft sprocket.
Loosen camshaft sprocket (counter-hold with 3036).
Pull off camshaft sprocket.

Fig 3: Camshaft Gear Retaining Bolt Installed Into Camshaft To Stop

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To guide oil seal extractor, screw securing bolt for camshaft sprocket -arrow- into camshaft as far as it will go by hand.
Remove inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in position with knurled screw.

Fig 4: Locating Knurled Screw And Turning Inner Part Of Extractor Against Camshaft Until Oil Seal Has Been Extracted

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lubricate threaded head of oil seal extractor 2085, place it in position and, exerting firm pressure, screw it into oil seal as far as possible.
Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

Installing

Lightly oil sealing lip of oil seal.

Fig 5: Installing Guide Sleeve 3241/2 Onto Camshaft Journal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install guide sleeve 3241/2 onto camshaft journal.
Slide oil seal over guide sleeve.

Fig 6: Pressing Oil Seal In Onto Stop With Press Sleeve 3241/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press oil seal in onto stop with press sleeve 3241/1. To do this use bolt 3241/5.

Fig 7: Installing Camshaft Sprocket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install camshaft sprocket.

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

Install securing bolt for camshaft sprocket (use counter-hold tool 3036).

Fig 8: 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 vibration damper marking with marking on lower part of toothed belt guard.

NOTE: If a piston is at TDC the valves could strike the piston when turning the camshaft. To avoid damage to valves and pistons the pistons must not be at TDC.

Install toothed belt onto camshaft sprocket.

Fig 9: Pulling Out Locking Pin, Locating Piston Of Toothed Belt Tensioning Element & Removing Stud

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out locking pin (arrow) and loosen piston of toothed belt tensioning element. Remove stud -1-.
Turn crankshaft two complete turns in engine direction of rotation, set again to TDC and check adjustment.
Install upper toothed belt guard.
Installing ribbed belt and tensioning element. Refer to Ribbed belt, removing and installing .

Tightening torques

Component		Nm
Camshaft sprocket to camshaft		65
Ribbed belt tensioner to bracket		25

Replacing intake camshaft oil seal

Removing

Remove ribbed belt. Refer to Removing ribbed belt .

Fig 10: Locating Connector At Camshaft Position Sensor G40

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Pull connector off Camshaft Position (CMP) Sensor -G40- (arrow).
Remove toothed belt guard (upper section). Refer to Toothed belt, removing and installing .
Remove Camshaft Position (CMP) Sensor housing.
Remove Camshaft Position (CMP) Sensor rotor and washer.

Fig 11: Adapter 2085/1 Threaded In Camshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To guide oil seal extractor, screw bolt 2085/1 by hand into camshaft as far as it will go.
Remove inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in position with knurled screw.

Fig 12: Screwing Threaded Head Of Seal Extractor With Forced Pressure Into Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lubricate threaded head of oil seal extractor 2085, place it in position and, exerting firm pressure, screw it into oil seal as far as possible.
Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

Installing

Lightly oil sealing lip of oil seal.

Fig 13: Installing Guide Sleeve 3241/2 Onto Camshaft Journal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install guide sleeve 3241/2 onto camshaft journal.
Slide oil seal over guide sleeve.

Fig 14: Pressing In Gasket Up To Stop Using Thrust Sleeve 3241/1 And Bolt 3241/3

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press oil seal in onto stop with press sleeve 3241/1. To do this use bolt 3241/3.
Install notch in Hall sensor rotor into intake camshaft.
Install washer (conical taper facing outward).
Install Camshaft Position (CMP) Sensor housing.

Install toothed belt guard (upper section).
Connect Camshaft Position (CMP) Sensor connector.
Install ribbed belt. Refer to Installing ribbed belt .

Tightening torques

Component		Nm
Camshaft Position (CMP) Sensor rotor to camshaft		25
Camshaft Position (CMP) Sensor housing to cylinder head		10