Removal And Installation: Camshafts

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Torque Wrench (5-50 Nm) V.A.G 1331
Hand Drill with Plastic Brush Attachment
Protective Eyewear
Sealant D 154 103 A1

Removing

NOTE:

The sealing surfaces on the bottom of the guide frame and on the top of the cylinder head must not be reworked.

The camshaft bearings are integrated in the cylinder head and in the guide frame. Before removing the guide frame, the adjuster and sprocket must be removed from the camshafts.

If the guide frame was loosened, the sealing plugs must be replaced.

-- Lock the camshafts and remove the adjuster and sprocket from the camshafts. Refer to VALVE TIMING, ADJUSTING .

-- Then, remove the camshaft clamp T40070.

Fig 1: Identifying Camshaft Clamp T40070 Installed On To Camshafts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Installing

WARNING:

To prevent injuries from shavings, wear protective goggles and protective clothing.

-- Remove any remaining sealant from the guide frame (out of the grooves as well) and from the cylinder head, for example using a rotating plastic brush.

CAUTION:

Make sure that no sealant residue enters the engine.

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

-- Lubricate the journal surfaces of the camshafts.

-- Place the guide frame upside down on a soft surface.

-- Insert the camshafts correctly into the guide frame.

Fig 2: Identifying Camshafts Inserted Correctly Into Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The intake camshaft with sensor wheel -2- points toward the camshaft position sensor -G40- -1-.
The camshafts must lie exactly in the axial bearings -3- of the guide frame.
The seal ends -4 and 5- must point upward or downward, they must not point to the side under any circumstances.

-- Turn the guide frame over, with the camshafts installed, hold the camshafts firmly in place in the guide frame while doing this.

-- Rotate the camshafts until the threaded holes -arrows- point upward.

Fig 3: Identifying Threaded Holes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check whether the camshafts still lie exactly in the axial bearings in the guide frame.

-- Install the camshaft clamp T40070 as shown onto the camshafts and tighten the bolts to 20 Nm.

Fig 4: Identifying Camshaft Clamp T40070 Installed On To Camshafts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn over the guide frame again.

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).

Fig 5: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lightly apply an even bead of sealant into the clean grooves -1 through 8- in the guide frame.

Fig 6: Identifying Bead Of Sealant Lightly Applied Into Clean Grooves Of Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Width of the sealant bead:

Grooves -1 through 5- : approximately 3.0 mm
Grooves -6 through 8- : approximately 4.0 mm

NOTE:

The sealant beads must be applied according to exact specifications, otherwise the excess sealant could get into the camshaft bearings.

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

Note the expiration date of the sealant.

-- Install the guide frame onto the cylinder head immediately.

-- Gently tighten the bolts working from the inside towards the outside in several stages.

-- Then, tighten the bolts to 8 Nm in the sequence indicated.

Fig 7: Identifying Tightening Bolts Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- After that, continue to tighten all bolts an additional 90° (1/4) turn.

-- The sealant must bulge outward slightly, even in the area of the chain compartment -arrows-.

Fig 8: Identifying Chain Compartment Sealant Locations

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Wipe off the sealant from the sealing surface facing the chain compartment cover.

-- Carefully press in the sealing plugs -A- until they reach the end of the chamfer -arrows-.

Fig 9: Identifying Sealing Plugs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the sealing plugs were pressed in too far, it must be pressed through and pressed in again up to the mark.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

-- Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt (30 Nm).

-- Fill the coolant. Refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .