Removal And Installation: Camshaft

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Counter-holder tool T10051
Removal tool T10052
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Sealant, black AMV 174 004 01

Removing

NOTE:

When using an exchanged cylinder head with camshaft installed, the contact surfaces between the lifters and cam lobes must be lubricated before installing the cylinder head cover.

The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.

When cylinder head is replaced, all coolant must also be replaced.

Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the tears have a width of max. 0.5 mm.

Do not mill the valve seats in the cylinder head; only grinding of the valves is permissible.

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

After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Always replace gaskets and seals.

-- Remove toothed belt TOOTHED BELT .

-- Remove bolts -1- for camshaft sprocket.

Fig 1: Identifying Camshaft Pulley Securing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull off camshaft sprocket from hub.

-- Loosen the bolt -1- for hub.

Fig 2: Identifying Counterhold T10051

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To do this, use the counter-holder T10051.

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

-- Set the valve stem removal tool T10052 in place and screw in the bolt for hub -1-.

Fig 3: Identifying Puller T10052

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Steadily fasten the valve stem removal tool to place the hub under tension until the hub is loosened from the taper of the camshaft.

NOTE:

Hold onto the valve stem removal tool with a wrench.

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

-- Remove cylinder head cover.

-- Mark the rocker lever shafts -arrows- with waterproof marker, to prevent switching them and thereby having to perform base setting for the pump-injector unit.

Fig 4: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the rocker lever shafts.

NOTE:

First loosen both outer bolts and then the inner bolts.

-- Remove tandem pump TANDEM PUMP .

-- First remove bearing caps 5, 1 and 3. Then loosen bearing caps 2 and 4, alternating in a diagonal sequence.

Fig 5: Identifying Bearing Caps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the camshaft.

Installing

NOTE:

When installing the camshaft, the cam lobes -arrows- for cylinder 1 must point upward.

Fig 6: Identifying Cam Lobes For Cylinder 1 Pointing Upward

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Do not interchange run in connecting rod bearing shells (mark).

When installing camshaft, make sure bearing shell retaining tabs are seated properly in bearing caps and cylinder head.

Before installing bearing cap, make sure that washers for cylinder head bolts are inserted in cylinder head.

-- Oil the running surfaces of the bearing shells.

-- Install bearing caps 2 and 4 with new bolts.

-- Fasten bearing caps 2 and 4, alternating in a diagonal sequence to 8 Nm + +90° (¹ /₄ turn).

-- Install bearing caps 5, 1 and 3 with new bolts.

NOTE:

Seal separating surfaces of bearing caps 1 and 5 with sealant, black AMV 174 004 01 BEARING CAPS 1 AND 5, SEALING SEPARATING SURFACES

Bearing cap 5 must seat flush with the outer edge of the cylinder head, otherwise leaks at the tandem pump may result.

-- Fasten the bearing caps 5, 1 and 3 to 8 Nm + +90° (¹ /₄ turn).

-- Install the camshaft seal CAMSHAFT SEAL .

-- Install the rocker lever shafts and first, fasten the new inner bolts -2- and then the new outer bolts -1-, evenly in a diagonal sequence to 20 Nm + 90° (¹ /₄ turn).

Fig 7: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the hub onto the camshaft.

-- Tighten the bolt -1- of the hub to 100 Nm.

Fig 8: Identifying Counterhold T10051

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To do this, use the counter-holder T10051.

-- Push the camshaft sprocket onto the hub.

NOTE:

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

Fig 9: Identifying Camshaft Pulley Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the camshaft sprocket to the central location in the slots.

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

-- Lock the hub with the rig pin 3359.

-- Toothed belt, installing and tensioning TOOTHED BELT .

-- Install tandem pump TANDEM PUMP .

NOTE: