Camshafts, Removing And Installing: Installing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Only install the camshafts with the Camshaft Fitting Tool:T40094A as described below. Otherwise the axial bearing in the guide frame will be destroyed and the cylinder head will have to be replaced.

WARNING:

Wear protective eyewear.

-- Remove sealant residue on the cylinder head and guide frame with rotating plastic brush.

CAUTION:

Make sure that no sealant residue enters the cylinder head and bearings.

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

-- Oil journal surfaces of camshafts.

Assemble the Camshaft Fitting Tool:T40094 as follows:

Fig 1: Identifying Bracket T40094/1 And Bracket T40094/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Left Cylinder Head:

-- Insert the Camshaft Fitting Tool - Bracket:T40094/2 in location -A-.

-- Insert the Camshaft Fitting Tool - Bracket:T40094/1 in location -D-.

Right Cylinder Head:

-- Insert the Camshaft Fitting Tool - Bracket:T40094/2 in location -B-.

-- Insert the Camshaft Fitting Tool - Bracket:T40094/1 in location -C-.

Continued for Both Sides:

Fig 2: Identifying Camshaft Insertion Tools T40094 And T40096

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The following procedure describes the left cylinder head.

The procedure is performed in the same order on the right cylinder head.

-- Insert the exhaust camshaft -1- in the Camshaft Fitting Tool - Bracket:T40094/1 and Camshaft Fitting Tool - Bracket:T40094/2 .

-- Rotate the camshaft so it can be secured in the TDC position with the straight-edge -arrow-.

-- Position the Camshaft Fitting Tool - T40096:T40096 on the camshaft splines so each of the arms on the clamping tool engages in half of the sprocket.

-- Tighten the clamping tool with the knurled bolt until the tooth faces align.

-- Insert the intake camshaft -2- in the Camshaft Fitting Tool:T40094A .

Fig 3: Identifying Intake Camshaft -2- In Camshaft Insertion Tool T40094

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The pin -3- must engage in the groove on the camshaft.

-- Slide the exhaust camshaft -1- toward the intake camshaft until the splines mesh.

-- Make sure the camshaft is positioned correctly:

Fig 4: Locating Camshaft Notches

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The notches -arrows- on both camshafts must face upward.

-- Place the guide frame -1- on the camshafts.

Fig 5: Identifying Guide Frame -1- On Camshafts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

All the camshaft bearings must lie on the camshafts.

-- Mount the Camshaft Fitting Tool:T40095 onto the camshafts by aligning the pliers and tension with the knurled nuts -2-.

-- Tension the camshafts by tightening the nuts -3-.

-- Make sure the alignment pins -arrows- are in the cylinder head. Insert any missing alignment pins.

Fig 6: Locating Cylinder Head Alignment Pins

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Note the expiration date of the sealing compound.

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: approximately 1.5 mm).

NOTE:

the illustration shows the guide frame without the camshafts.

Fig 8: Identifying Sealant Beads -Arrows- On Clean Sealing Surfaces Of Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn the guide frame around.

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than specified.

-- Apply sealant beads -arrows- on clean sealing surfaces of guide frame as shown in illustration.

The grooves -arrows- of sealing surface must be completely filled with sealant.
The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

NOTE:

Sealant beads must not be thicker than specified, otherwise extra sealant can enter camshaft bearing.

The guide frame must be installed within 5 minutes after application of sealant.

CAUTION:

The engine could be damaged.

Make sure all the roller rocker levers are seated correctly on the valve stem ends and the adjusters.

-- Place the guide frame on the cylinder head immediately with both camshafts and the Camshaft Fitting Tool:T40095 .

Fig 9: Identifying Left Cylinder Head Guide Frame, Tightening Specifications and Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

After installing guide frame, sealant must dry for approximately 30 minutes.

-- Tighten the guide frame bolts by hand evenly in the sequence -1 through 18-.

The guide frame must be touching the entire contact surface of the cylinder head.

-- Fasten guide frame bolts in sequence -1 through 18- until they stop.

-- Remove the Camshaft Fitting Tool:T40095 and the Camshaft Fitting Tool - T40096:T40096 .

Install in reverse order of removal. Note the following:

NOTE:

Do not start the engine for approximately 30 minutes after installing the camshafts. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons).

After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

-- Install the left or right cylinder head cover. Refer to CYLINDER HEAD COVER, REMOVING AND INSTALLING .

Left Cylinder Head:

-- Replace the camshaft seal. Refer to CAMSHAFT SEAL, REMOVING AND INSTALLING .

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

-- Install the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

Right Cylinder Head:

-- Replace the front cover on the cylinder head.

-- Drive the new cover in with a suitable drift until it is flush.

Continued for Both Sides:

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