Removal And Installation: Camshafts

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

Special tools and workshop equipment required

Puller -T40001-
Retainer -3036-
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 tension on the toothed belt must be released.

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

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

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

With a divided toothed belt guard, refer to TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD .
Without a divided toothed belt guard, refer to TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD .

-- Loosen the camshaft sprocket bolt approximately 10 mm (use the retainer -3036-).

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the camshaft sprocket using the puller -T40001-, claw -T40001/6- and claw -T40001/7-. The puller -T40001- supports itself on the bolt -arrow-.

Fig 2: Identifying Tools To Remove Crankshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the bolt and camshaft sprocket.

-- Remove the toothed belt guard bolts and guard from the rear of the cylinder head.

-- Loosen the bolts for the guide frame evenly working 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 UNITED STATES, 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 rocker arms make contact correctly on the valve stems.

-- Lubricate the journal surfaces of the camshafts.

-- Carefully install the camshafts into the camshaft bearings in the cylinder head. The cam lobes -A- for cylinder 4 must face toward one another.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Apply an even, light, bead of sealant -D 154 103 A1- in the clean groove in the guide frame.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

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

Placing the guide frame in place and tightening the bolts should occur without interruption, since the sealant begins to harden immediately when the sealing surfaces come into contact.

Note the expiration date of the sealant.

-- Place the guide frame on the cylinder head.

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

-- Then, tighten the bolts in sequence -1 through 6- to 8 Nm + 90° (1/4) additional turn.

Fig 6: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the cap approximately 1 to 2 mm deep using the thrust piece -3334-. See item 25.

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

-- Install the rear toothed belt guard.

-- Insert the woodruff key into the camshaft.

-- Install the camshaft sprocket. Hold the camshaft sprocket using the retainer -3036- and tighten the bolt. Tightening specification, refer to VALVETRAIN OVERVIEW .

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

When rotating the camshaft, the pistons may not be at TDC for any cylinder. The valves/pistons may be damaged.

Be sure the woodruff key is properly seated.

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

With a divided toothed belt guard, refer to TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD .
Without a divided toothed belt guard, refer to TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD .

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

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

Further installation is in reverse order of removal.