Removal And Installation: Camshaft: Installing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

All roller rocker levers need to rest on the valve stem ends.

-- Remove any sealant residue on the cylinder head using the flat blade scraper.

-- In the event the crankshaft has been rotated in the meantime: Place the piston of the 1st cylinder on the top dead center and turn the crankshaft back a little bit.

-- Remove any sealant residue from the groove on the cylinder head cover as well as on the sealing surfaces.

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

-- Lubricate the running surfaces of both camshafts.

-- If the camshafts are replaced, the markings -arrow- need to be transferred onto the new camshafts.

Fig 1: Mark The Camshaft Sprocket

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CAUTION:

Risk of damaging valves and piston crowns.

The crankshaft must not be in the "TDC" position when installing the camshafts.

-- Place the intake camshaft -A- in the cylinder head. Turn the cam lobes from cylinder 4 -arrows- upward.

Fig 2: Identifying Intake Camshaft And Cylinder Head

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-- Turn the exhaust camshaft until the markings -A- and -B- align.

Fig 3: Locating Alignment Marks

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-- Apply the sealant on the clean sealing surface of the cylinder head cover as illustrated -arrows-.

Fig 4: Applying Silicone Sealant

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Thickness of sealant bead: 2 to 3 mm.

NOTE:

The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

-- Secure the camshaft and place the cylinder head cover with the camshaft on the cylinder head.

-- Lightly push on the cylinder head cover by hand and while doing so turn the camshaft slightly so that the cylinder head cover lays free of tension on the cylinder head.

Fig 5: Turning Camshafts

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-- Replace the cylinder head cover bolts.

-- Tighten the bolts in several steps. Tightening sequence, refer to Figure.

NOTE:

Do not tilt the cylinder head cover when mounting it.

-- Turn the intake camshaft in direction of -arrow 1- until the marking -3- aligns with the Camshaft Locks T40271/2.

Fig 6: Identifying Markings And Camshaft Clamp T40271/2

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-- Slide the Camshaft Locks T40271/2 into the chain sprocket splines in the direction of -arrow 2-.

-- Turn the exhaust camshaft in the direction of -arrow 1- until the marking -3- aligns with the Camshaft Locks T40271/1.

Fig 7: Identifying Markings And Camshaft Locating Tool T40271/1

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-- Slide the Camshaft Locks T40271/1 into the chain sprocket splines in the direction of -arrow 2-.

-- Rotate the vibration damper using the Counterhold - Vibration Damper T10355 into the "TDC" position.

Fig 8: Locating TDC

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The notch on the vibration damper and the marking on the lower cover for timing chain must be opposite one another -arrow-.

-- Position the markings on the chain links -arrows- at the chain sprockets -1- to mount the camshaft timing chain.

Fig 9: Identifying Markings On Chain Links

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-- Install the upper guide track -2-.

-- Use the Adapter T40266 to turn the exhaust camshaft in the direction of -arrow 1-, slide out the Camshaft Locks T40271/1 from the chain sprocket splines in the direction of -arrow 2- and release the camshaft.

Fig 10: Identifying Assembly Tool T40266

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-- Guide the tensioning rail -2- upward and install the bolt -1-.

Fig 11: Move Tensioning Rail Up And Install Bolt

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-- Use the Adapter T40266 to turn the intake camshaft in the direction of -arrow 1-, slide out the Camshaft Locks T40271/2 from the chain sprocket splines in the direction of -arrow 2- and release the camshaft.

Fig 12: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

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-- Check the valve timing. The camshaft timing chain and cylinder head -arrows- must align with the markings on the chain sprocket.

Fig 13: Identifying Markings On Chain Sprocket

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-- The markings for the camshaft timing chain and the camshaft timing chain glide track -2- must align.

-- The notch on the vibration damper must be opposite the marking on the lower timing chain cover -3-.

NOTE:

If the self-made markings are no longer visible, check the valve timing, refer to VALVE TIMING, CHECKING .

-- Mount the bearing bracket and the bolts -arrows- hand-tight.

Fig 14: Identifying Bolts

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-- Remove the Tensioner Locking Tool T40267.

-- Tighten the bolts -arrows-, refer to OVERVIEW - CAMSHAFT TIMING CHAIN .

-- Install the pilot valves -item 6.

-- Install the upper timing chain cover, refer to UPPER TIMING CHAIN COVER .

-- Install the vacuum pump, refer to VACUUM PUMP .

-- Install the high pressure pump, refer to HIGH PRESSURE PUMP .

-- After performing work on the chain drive the adaptation value in the engine control module must be adapted. To do this turn on the ignition and select the following menu items on the Vehicle Diagnostic Tester:

01 - Engine electronics
Guided functions
01 - Adaptation after repair work on the chain drive

Install in reverse order of removal. Note the following: