Camshaft, Removing And Installing: Installing

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NOTE:

The crankshaft must not be at "TDC".

Replace the bolts that were tightened with an additional turn after removing them.

-- Make sure all the roller rocker levers lie correctly on the ends of the valve stems and are clipped onto the respective hydraulic lifters.

In the case that the crankshaft has been turned in the meantime:

-- Position the crankshaft at "TDC" ; the V-shaped cut-out on the three-layer chain sprocket points in an imaginary vertical line -arrows- centered between the camshaft chain sprockets.

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-- Then turn the crankshaft 90° counter-clockwise out of "TDC".

CAUTION:

Risk of contaminating the lubricating system and the bearing.

Cover open engine components.

WARNING:

Risk of eye injury.

Wear protective eyewear!

-- Remove any sealant residue on the cylinder head using the flat-bladed scraper.

-- Remove any sealant residue from the groove on the cylinder head cover as well as on the sealing surfaces.

-- Clean any oil or grease off the sealing surfaces.

CAUTION:

The engine could be damaged.

Bring all cam adjustment actuator pins into the installed position.

-- Press down the cam adjustment actuator pins in the direction of -arrow- by hand.

Fig 1: Bring the Cam Adjustment Actuators into the Installed Position

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The adjusting element pins must not be in the outward position.

-- Coat the camshaft contact surfaces with engine oil.

-- Position the exhaust camshaft in the cylinder head and turn the lobes -arrows- from cylinder 4 upward.

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CAUTION:

Risk of loosening the spring-loaded ball for the camshaft sliding bar.

Only slide back and forth the intake camshaft spacers in the normal area of the window

-- Insert the intake camshaft in the cylinder head cover.

The spacers must be pushed away from the chain sprocket in the direction of -arrows-.

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-- With the intake camshaft installed push the front and rear sliding bar ends to each other in direction of -arrows-.

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-- Align the intake camshaft in the "TDC" point.

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The marking -arrow A- must align with the locating tab -arrow B- on the cylinder head cover.

-- Apply sealant to the clean sealing surfaces of the cylinder head cover -arrows- as shown.

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Sealant Bead Thickness: 1.5 To 2.5 mm

-- Secure the camshaft and place the cylinder head cover with the camshaft on the cylinder head.

-- Lightly press on the cylinder head cover by hand and at the same time slightly push the camshafts back and forth in the direction of -arrows- until the cylinder head cover lays on the cylinder head >>without tension<<.

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-- Tighten the bolts in multiple steps. Refer to Figure.

NOTE:

Pay attention that the cylinder head cover is not tilted.

-- Turn the intake camshaft with the :T40266 in the direction of -arrow A- until the marks -1 and 2- align. Push the :T40271/2 in the chain sprocket splines in the direction of -arrow B-.

Fig 2: Identifying Intake Camshaft With Adapter T40266

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-- Turn the exhaust camshaft with the :T40266 in the direction of -arrow A- until the marks -1 and 2- align. Push the :T40271/1 in the chain sprocket splines in direction of -arrow B-.

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NOTE:

The mark -2- is offset slightly to the right.

-- Turn the crankshaft on the hex fitting to the "TDC point".

The flattened surface -1- must be on top.

Fig 3: Identifying Assembly Tool - Turning Over Tool T10531/3
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-- Remove the :T10531/4 and the :T10531/3 .

Further installation is performed in reverse order of removal, while noting the following:

NOTE:

Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts information.

-- Install the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .

-- Install the vacuum pump. Refer to VACUUM PUMP, REMOVING AND INSTALLING / VACUUM PUMP, REMOVING AND INSTALLING [CYMC, DFVA, CWGD, DBPA, DECA] .

-- Install the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Install the oil separator. Refer to OIL SEPARATOR, REMOVING AND INSTALLING .

-- Install the ignition coils with power output stages. Refer to IGNITION COILS WITH POWER OUTPUT STAGES, REMOVING AND INSTALLING .

-- Install the air filter housing. Refer to OVERVIEW - AIR FILTER HOUSING [4-Cylinder Direct Injection 2.0L 4V TFSI Engine] / AIR FILTER HOUSING, REMOVING AND INSTALLING [4-Cylinder Direct Injection 2.0L 4V TFSI Engine] .

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Connect the coolant hoses with the connector coupling. Refer to RADIATOR/RADIATOR FAN / OVERVIEW - RADIATOR/RADIATOR FAN .

-- Connections and wire routing. Refer to the appropriate Wiring Diagram(s).

-- If work is performed on the chain drive, perform the "01 - mechanical engine, functions" listed adaptation. Refer to Vehicle Diagnostic Tester.