Removal And Installation: Camshafts

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

puller T40001
Counter-holder tool 3036
Sealant D 154 103 A1

Removing

NOTE:

The sealing surfaces on the guide frame (bottom) and on the cylinder head (top) must not be worked.

Camshaft bearings are integrated in the cylinder head or in the guide frame. Before removing the guide frame, the tension on the toothed belt must be released.

If the guide frame was loosened, the camshaft seal and cap must be replaced.

-- Remove the camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

-- Remove the toothed belt, refer to one of the following:

-- Loosen the camshaft gear. Use the 3036 to do so.

Fig 1: Identifying Use Of Counterhold On Camshaft Gear Using 3036 Retainer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the camshaft gear using the T40001, T40001/6 and the T40001/7.

Fig 2: Identifying Puller T40001, Claw T40001/6 And Claw T40001/7

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the toothed belt guard bolts from the cylinder head.

-- Loosen the guide frame bolts evenly from the outside toward the inside and remove the guide frame.

-- Carefully remove the camshaft upward and place it on a clean surface.

-- Remove the old sealant from the guide frame groove as well as from the sealing surfaces.

Fig 3: Identifying Old Sealant On Guide Frame Groove And From Sealing Surfaces

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Prevent dirt and adhesive residue from entering the cylinder head.

Installing

NOTE:

Sealing surfaces must be completely free of oil and grease.

The pistons must not be positioned at Top Dead Center (TDC).

Make sure that all roller cam followers make contact correctly on the valve stem ends.

-- Oil the journal surfaces of the camshafts.

-- Carefully install the camshafts into the camshaft bearings of the cylinder head. Cam lobes -A- of cylinder 4 must face each other.

Fig 4: Identifying Marking On Camshaft Gear Aligned With Marking On Toothed Belt Guard

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Recesses -arrows- must point to each other vertically.

-- Apply an even, slightly raised bead of Sealant D 154 103 A1 into the clean grooves of the guide frame.

Fig 5: Identifying Old Sealant On Guide Frame Groove And From Sealing Surfaces

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Note the expiration date of the sealing compound.

Sealant must not be applied too thick. Wipe off excess sealant if necessary using a lint free cloth.

Installing and tightening the guide frame bolts should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces.

-- Place the guide frame on the cylinder head.

-- Tighten the new bolts from the inside working toward the outside in several stages.

-- Tighten bolts in the sequence shown.

Fig 6: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drive in the cap using the 3334 approximately 1 to 2 mm deep, see -item 25- in the VALVETRAIN ASSEMBLY OVERVIEW .

-- Install the camshaft seal. Refer to EXHAUST CAMSHAFT SEAL .

-- Install the rear toothed belt guard.

-- Insert the fitted key into the camshaft.

-- Install the camshaft gear. To tighten the bolt, hold the camshaft gear in place using the 3036. Tightening specification, refer to VALVETRAIN ASSEMBLY OVERVIEW .

Fig 7: Identifying Use Of Counterhold On Camshaft Gear Using 3036 Retainer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

When turning the camshaft, the pistons may not be at TDC for any cylinder. Valves/pistons may be damaged.

Be sure the fitted key is properly seated.

-- Install the toothed belt, refer to one of the following:

-- Install the camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

-- Install the cylinder head cover. Refer to CYLINDER HEAD COVER .

The rest of the assembly is basically a reverse of the removal sequence.