Camshafts, removing and installing: Installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Contact Surfaces Of Bearing Caps 7 And 8

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Before installing, lightly coat contact surfaces of bearing caps 7 and 8 with grease "G 052 723 A2".

Requirements

When installing the camshafts, the cam lobes for cylinder 1 must point upward.

Insert support element in cylinder head and install roller rocker lever onto respective valve stem end and support element.

Fig 2: Identifying Valve Stem Ends & Support Elements

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Ensure that all roller rocker levers seat properly on valve stem ends - 1 - and are clipped onto respective support elements - 2 -.
Oil running surfaces of both camshafts.
Place respective camshaft carefully in camshaft bearings of cylinder head. Observe camshaft identification Camshaft identification, valve timing under Valve stem seals, replacing .

Fig 3: Points Of Intake And Exhaust Camshaft Bearing Cap

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NOTE:

Observe installed position of bearing caps:
Points of intake and exhaust camshaft bearing caps - arrow A - face outwards.
Identification on bearing caps is legible when read from intake side.

Fig 4: Identifying Intake Camshaft And Exhaust Camshaft

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A - Intake camshaft

Tighten bearing caps 5 and 9 alternately and diagonally to 5 Nm and 1/8 turn (45 ° ) further.
Install bearing caps 1 and 13 and tighten to 5 Nm and 1/8 turn (45 ° ) further.
Install bearing cap 7 and tighten to 5 Nm and 1/8 turn (45 ° ) further.
Install bearing caps 3 and 11 and also tighten to 5 Nm and 1/8 turn (45 ° ) further.

Fig 5: Identifying Intake Camshaft And Exhaust Camshaft

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B - Exhaust camshaft

Tighten bearing caps 6 and 10 alternately and diagonally to 5 Nm and 1/8 turn (45 ° ) further.
Install bearing caps 2 and 14 and tighten to 5 Nm and 1/8 turn (45 ° ) further.
Install bearing cap 8 and tighten to 5 Nm and 1/8 turn (45 ° ) further.
Install bearing caps 4 and 12 and also tighten to 5 Nm and 1/8 turn (45 ° ) further.

Position the camshafts in cylinder head to TDC No. 1 cylinder.

Fig 6: Identifying Camshaft Bar T10068 Engage In Both Shaft Grooves

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The camshaft bar T10068 A must engage in both shaft grooves.
Before installing, check the control housing screen for contamination Check the control housing screen for contamination under Assembly overview .
Before installing control housing, lightly lubricate surfaces in control housing contacting camshaft seals.
Lightly lubricate camshaft seals and slowly push control housing over camshaft seals.

Fig 7: Locating Control Housing-To-Cylinder Head Bolts

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Install control housing - arrows - and fasten with 8 Nm.

How to adjust valve timing, refer to Valve timing, adjusting .

Fig 8: Locating 3 mm Holes In The Cylinder Head Gasket

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Clean old sealing compound from the 3 mm holes in cylinder head gasket - arrows -.

NOTE:

With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

Fill the 3 mm holes in the cylinder head gasket with sealing compound 174 004 01 and apply an elevated level of sealing compound to these respective areas.

NOTE:

Sealing compound AMV 174 004 01 hardens quickly.

Lubricate O-ring for oil channel seal and install with oil seal into cover.
Coat sealing surface of cover with sealing compound "AMV 176 501" and install immediately.
First insert all fastening bolts and lightly tighten.
Thereafter fasten the bolts M8 to 23 Nm, and then fasten bolts M6 to 8 Nm.

Install camshaft roller chain tensioner and fasten to 40 Nm.
Install cylinder head cover and intake manifold, refer to Cylinder head cover, removing and installing .