Camshaft, Removing And Installing

Special tools and workshop equipment required

Counterhold - Crankshaft Sprocket 3415
Torque Wrench 1331 5-50Nm VAG1331
Torque Wrench 1332 40-200Nm VAG1332
Sealant AMV 174 004 01

Removing

-- Remove the upper toothed belt guard.

-- Turn the crankshaft the direction of engine rotation and move the camshaft sprocket to Top Dead Center (TDC) cylinder 1.

Fig 1: Turning Crankshaft In Direction Of Engine Rotation And Moving Camshaft Sprocket To Top Dead Center (TDC) Cylinder 1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marking on camshaft sprocket must line up with the arrow on toothed belt guard -arrows-.

-- Loosen the tensioning roller and remove the toothed belt from the camshaft sprocket.

-- Then turn the crankshaft slightly backward.

-- Remove the camshaft sprocket. To loosen the bolt, hold the camshaft sprocket firmly using the Counterhold - Crankshaft Sprocket 3415.

Fig 2: Identifying Counter-holding 3415 & Camshaft Pulley Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove woodruff key from the camshaft.

-- Remove the cylinder head cover.

-- Remove bearing caps 5, 1 and 3 first. Loosen bearing caps 2 and 4 in alternation and in diagonal sequence.

NOTE:

The numbers are stamped into the bearing cap.

Installing

Conditions

The pistons must not be positioned at TDC.
When installing the camshafts, the cam lobes for cylinder 1 must point upward.

NOTE:

When installing, make sure the bearing cap is centrally positioned. Before installing, set bearing caps in place and determine installation position.

Fig 3: Identifying Correct & Incorrect Bearing Cap Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lubricate the running surfaces of both camshaft.

-- Install the camshaft.

-- Tighten bearing caps 2 and 4 alternately and in a diagonal sequence to 20 Nm.

-- Lightly coat the contact surface of bearing cap 1 with Sealant AMV 174 004 01.

-- Install bearing cap 3, 1 and 5 and tighten them to 20 Nm.

-- Mount the woodruff key into the camshaft.

-- Install camshaft sprocket. To tighten the bolt, hold the camshaft sprocket firmly using the Counterhold - Crankshaft Sprocket 3415.

Fig 4: Identifying Counter-holding 3415 & Camshaft Pulley Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tightening specification: 100 Nm

CAUTION:

Danger of causing damage to the pistons and the valves.

When turning camshaft, pistons may not be at TDC for any cylinder.

Assemble in reverse order of disassembly.

-- Install the toothed belt, refer to TOOTHED BELT, REMOVING AND INSTALLING .

NOTE:

After installing new hydraulic valve lifters, the engine may not be started only after approximately 30 minutes. Hydraulic equalization elements must seat themselves. Otherwise the valves will impact the pistons.