Removal And Installation: Camshafts

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Diesel Injection Pump Locking Pin 3359
Camshaft Gear Counter-Holder T10051
Puller T10052
Camshaft Fitting Tool T40094
Camshaft Clamping Tool T40095
Camshaft Tensioning Tool T40096
Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Hand Drill with Plastic Brush Attachment
Protective Eyewear
Silicone Adhesive Sealant D 176 501 A1

Removing

-- Remove the toothed belt from the camshaft and the high pressure fuel pump. Refer to TOOTHED BELT .

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

-- Remove bolts -1- from the camshaft gear.

Fig 1: Identifying Camshaft Pulley Securing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the camshaft gear from the hub.

-- Counter-hold the hub using the camshaft gear counter-holder T10051 and loosen the hub bolt -1-.

Fig 2: Identifying Counterhold T10051

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the bolt for the hub by approximately 2 turns.

-- Position the puller T10052 and align it to the bores in the hub.

Fig 3: Identifying Puller T10052

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolts -1-.

-- Tension the hub by tightening the puller T10052 -2- evenly until it can be removed from the camshaft taper.

NOTE:

Hold the puller T10052 with a 30 mm wrench.

-- Remove the hub from the cone of the camshaft.

-- Remove the vacuum pump. Refer to VACUUM PUMP .

-- Remove the bearing frame bolts and nuts in sequence -24 through 1-.

Fig 4: Identifying Bearing Frame Bolts Removal Sequence -24 Through 1-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bearing frame.

-- Carefully remove the camshafts.

Installing

NOTE:

Note the expiration date of the silicone adhesive Sealant D 176 501 A1.

Seal the separating surfaces between the bearing frame and cylinder head using silicone adhesive Sealant D 176 501 A1.

CAUTION:

Only install the camshafts with the camshaft fitting tool T40094 as described below. Otherwise the axial bearing in the bearing frame will be destroyed and the cylinder head will have to be replaced.
Make sure that no sealant residue enters the cylinder head and bearings.

WARNING:

Wear safety glasses.

-- Remove any sealant still on the cylinder head and bearing frame with a rotating plastic brush.

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

-- Oil the journal surfaces of camshafts.

Assemble the camshaft fitting tool T40094 as follows:

-- Remove the mounts T40094/3, T40094/4 and T40094/5 from the base plate. Loosen the threaded connections from below.

Fig 5: Identifying Mounts T40094/1 To T40094/8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the camshaft fitting tool T40094 mounts are not marked, mark the removed mounts, for example, with numbers, to assure it can be assembled later.

-- Install the mounts T40094/9 and T40094/10 in the empty outer locations.

Fig 6: Identifying Mounts T40094/1, T40094/2, T40094/9, T40094/10 and T40094/11

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position mount T40094/2 on location "A" and mount T40094/1 on location "F".

-- First install the intake camshaft as illustrated. Make sure the indentation -arrow- for the cylinder head bolt faces >>outward<<.

Fig 7: Identifying 0.50 mm Feeler Gauge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the 0.50 mm feeler gauge and slide the mount T40094/8 into the groove on the intake camshaft.

-- Install the exhaust camshaft.

-- Secure the exhaust camshaft above the groove -arrow- with the cover T40094/11.

Fig 8: Identifying Cover T40094/11

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mount the tensioning tool T40096/1 on the toothed gears on the exhaust camshaft.

CAUTION:

Make sure the clamping jaw marked with an arrow is on the wider gear.

-- Tighten the tensioning tool T40096/1 with the knurled thumb screw until the tooth faces align. Use a 13 mm open end wrench if necessary.

Fig 9: Identifying Tensioning Tool T40096/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Position the bearing frame on the camshafts.

All the camshaft bearings must align on the camshafts.

-- Position the camshaft clamping tool T40095 as illustrated and secure the camshafts in the bearing frame.

Fig 10: Identifying Camshaft Clamping Tool T40095

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the cover T40094/11.

-- Remove the mount T40094/8 from the groove in the intake camshaft.

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 3 mm).

Fig 11: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Apply the silicone adhesive Sealant D 176 501 A1 to the clean sealing surface of the cylinder head as illustrated. The sealant bead must be:

Fig 12: Identifying Silicone Adhesive Sealant Pattern

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

2 to 3 mm thick
Apply on the inner side in the area with the threaded holes

NOTE:

The sealant beads must not be thicker than 2 to 3 mm or the excess sealant can enter the camshaft bearing.

-- Remove the camshafts with the bearing frame and the camshaft clamping tool T40095 from the camshaft fitting tool T40094.

-- Carefully install the camshafts and bearing frame to the cylinder head.

-- First, tighten the bearing frame bolts and nuts by hand in sequence -1 through 24-.

Fig 13: Identifying Bearing Frame Bolts And Nuts Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Tighten the bearing frame bolts and nuts in sequence -1 through 24-.

Tightening specifications, see -items 2 and 3- in the VALVETRAIN OVERVIEW .

-- Remove the camshaft clamping tool T40095 and the tensioning tool T40096/1.

-- Replace the camshaft seal. Refer to CAMSHAFT SEAL .

-- Drive a new cap onto the cylinder head with a suitable drift until it is flush.

The rest of the installation is performed in reverse order of removal, noting the following:

NOTE:

After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic lash adjusters must seat themselves (otherwise the valves will crash into the pistons).

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

-- Place the hub on the camshaft.

-- Counterhold the hub with the camshaft gear counter holder T10051 and tighten the hub bolt -1-.

Fig 14: Identifying Counterhold T10051

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tightening specification, see -item 11- in the TOOTHED BELT OVERVIEW .

-- Push the camshaft gear onto the hub.

Fig 15: Identifying Camshaft Pulley Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The toothed segment -arrow- of the camshaft gear must face upward.

-- Install the bolts -1- into the camshaft gear by hand to eliminate play.

-- Lock the hub using the diesel injection pump locking Pin 3359.

-- Install and tension the toothed belt. Refer to TOOTHED BELT .

-- Install the vacuum pump. Refer to VACUUM PUMP .

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