Camshafts, removing and installing

Special tools, testers and auxiliary items required 

Fig 1: Locking Pin T40069

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Locking pin T40069

Fig 2: Camshaft Locator T40070 (2X)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Camshaft locator T40070 (2x)
• Hand drill with plastic brush attachment
• Protective glasses
• Sealant

Removing 

• Remove cylinder head cover: Left → Left cylinder head cover, removing and installing  , right → Right cylinder head cover, removing and installing .
• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Remove camshaft timing chains from camshafts → Detaching timing chains from camshaft, removing and installing chain tensioner .
• To remove right camshafts, the vacuum pump for brake booster must be removed → Vacuum pump for brake booster, removing and installing .

Fig 3: Tightening Guide Frame Bolts In Sequence

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• Loosen guide frame bolts in sequence - 22 to 1  -.

• Carefully remove guide frame.
• Mark camshafts and remove.

Installing 

• Using rotating plastic brush, remove any remaining sealant from cylinder head and guide frame.

• Clean sealing surfaces, they must be free of oil and grease.
• Oil journal surfaces of camshafts.
• Place guide frame onto a soft surface on workbench.

Fig 5: Setting Camshafts Into Guide Frame

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• Set camshafts into guide frame.

• The placement of camshafts must be exactly within axial bearings - arrows  - of guide frame.
• The ends of the piston rings - 1  - and - 2  - must face upward or downward, and must never face sideways.

• Turn over guide frame with installed camshafts, thereby holding camshafts tight within guide frame.

Fig 6: Identifying Threaded Holes In Camshafts Must Face Upward

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• Rotate camshafts until threaded holes - arrows  - point upward.
• Check whether camshafts still lie exactly in axial bearings of guide frame.

Fig 7: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads And Locating Bolts

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• Mount camshaft locating tool T40070 as shown in the illustration and tighten bolts - arrows  - to 20 Nm.

Fig 8: Cutting Tube Nozzle At Front Marking

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• Cut tube nozzle at front marking (jet dia. approx. 1 mm).
• Turn guide frame around again.

Fig 9: Applying Small Quantity Of Sealant In Seal Groove In Area Of Camshaft Adjuster Solenoid Valve Opening

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• Apply a small quantity of sealant in seal groove - 3  - in area of camshaft adjuster solenoid valve opening - arrows  -.
• Press seal into guide frame and wipe off escaping sealant on seal and guide frame.
• Apply sealant beads - 1  - , - 2  - and - 4  - on clean sealing surfaces of guide frame as shown in illustration.

• Thickness of sealant bead: 1.0 mm.

• Attach guide frame on cylinder head immediately.

Fig 10: Tightening Guide Frame Bolts In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Hand-tighten guide frame bolts equally, in sequence - 1 to 22  -.

• The guide frame must be in contact with the entire contact surface of the cylinder head.

• Fasten guide frame bolts in sequence - 22 to 1  - until they stop.

• Drive in sealing plugs flush.

Further installation is in reverse order of removal, note the following:

• Install vacuum pump for brake booster → Vacuum pump for brake booster, removing and installing .
• Install camshaft timing chains onto camshafts → Detaching timing chains from camshaft, removing and installing chain tensioner .
• Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Install cylinder head cover: Left → Left cylinder head cover, removing and installing  , right → Right cylinder head cover, removing and installing .

Torque specifications