Camshaft, Removing And Installing: Installing

• Tightening specifications. Refer to OVERVIEW - VALVETRAIN .

• Crankshaft -1- secured in "TDC" using Crankshaft Locking Pin:T40069  .
  Fig 1: Crankshaft Locking Pin T40069

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The hydraulic adjusting elements and roller rocker lever are inserted.

-- Remove the sealant residue on the cylinder head and guide frame, for example using a rotating plastic brush.

-- Clean the sealing surfaces; they must be free of oil and grease.

-- Check the screen -arrow- for dirt; clean it if necessary.

Fig 2: Identifying Screen

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Oil the camshaft running surfaces.

-- Insert the camshafts in the guide frame.

Fig 3: Compression Ring Ends -1, 2 And 3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The placement of the camshafts must be exactly within the axial bearings -arrows- of the guide frame.
• The compression ring ends -1, 2 and 3- must face up or down. They must never face sideways.

-- Rotate the guide frame with the camshafts inserted while holding them securely in the frame.

-- Rotate the camshafts until the threaded holes -arrows- face upward.

Fig 4: Camshafts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check if the camshafts still lie in the guide frame axial bearings.

-- Secure the camshafts for cylinder bank 1 in "TDC" using the Camshaft Clamp:T40133/1  -arrows- (25 Nm).

Fig 5: Camshaft Clamp -T40133/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the camshafts for cylinder bank 2 in "TDC" using the Camshaft Clamp:T40133/2  -arrows- (25 Nm).

Fig 6: Camshaft Clamp -T40133/2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Be sure to check the expiration date of the sealant.

Fig 7: Cut Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm).

-- Rotate the guide frame again.

-- Apply sealant beads -4 through 8- to the clean sealing surfaces on the guide frame as shown in the illustration.

Fig 8: Applying Sealant Beads -4 Through 8- To Clean Sealing Surfaces On Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Sealant bead thickness: 2.0 mm

-- Apply sealant beads -1 through 3- to the clean sealing surfaces on the guide frame as shown in the illustration.

• Sealant bead thickness: 2.5 mm.

-- Place the guide frame on the cylinder head.

Fig 9: Aligning Guide Frame And Cylinder Head Using Locating Pins T40116

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the Locating Pins:T40116  into the guide frame and cylinder head.

-- Tighten the camshaft guide frame bolts. Refer to Figure.

Fig 10: Camshaft Guide Frame Bolt Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove any oil and grease from the hole for the plug in the cylinder head.

Fig 11: Camshaft Sealing Plug

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Coat the outer edge of the plug -arrow- with sealant. Refer to Parts Information.

-- Drive in the sealing plugs until they are flush.

-- Remove the Locating Pins:T40116  with the Injector/Combustion Chamber Seal Tool Set - Sliding Hammer:T10133/3  .

Fig 12: Remove The T40116 Using T10133/3

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Install in reverse order of removal, Note The Following: 

-- Install the Camshaft Adjustment Valve 1 -N205- / Camshaft Adjustment Valve 2 -N208-. Refer to OVERVIEW - CYLINDER HEAD .

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

-- Install the vacuum pump. Refer to appropriate service information .

-- Position the camshaft timing chain on the camshafts. Refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .