Removal And Installation: Camshaft

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 

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

-- Then, remove the camshaft clamp T40070.

Fig 1: Attempting To Rotate Exhaust Camshaft At Recess Using An Open-End Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Installing 

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

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

-- Oil the journal surfaces of the camshafts.

-- Place the guide frame on a soft surface.

-- Insert the camshafts correctly into the guide frame.

Fig 2: Insert Camshafts Into Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The intake camshaft with the sensor wheel -2- faces toward the camshaft position sensor -G40- -1-.
• The camshafts must lie exactly in the axial bearings -3- of the guide frame.
• The ends of the seals -4 and 5- must face up or down. They must not face to the side.

-- Turn over the guide frame slightly 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 Camshafts Threaded Holes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 4: Attempting To Rotate Exhaust Camshaft At Recess Using An Open-End Wrench

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: 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 of the guide frame -1 through 8-.

Fig 6: Applying An Even Bead Of Sealant Into Clean Grooves Of Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Width of sealant bead:

• Grooves -1 through 5- : approximately 3.0 mm
• Grooves -6 through 8- : approximately 4 mm

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

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

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

Fig 7: Cylinder Head Bolts Tighten Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- The sealant must squeeze out slightly, even in the chain compartment area -arrows-.

Fig 8: Identifying Chain Compartment

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Wipe off the excess sealant on the sealing surface facing the timing chain cover.

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

Fig 9: Pressing In Sealing Plugs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The rest of the installation follows the reverse of the removal procedure. 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 COOLANT, DRAINING AND FILLING .