Removal And Installation: Camshaft: Removing

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:

The sealing surfaces of the lower cylinder head cover and on the upper cylinder head must not be reworked.

The camshaft bearings are integrated in the cylinder head or cylinder head cover. Before removing the cylinder head cover, release the tension on the camshaft timing chain.

-- Remove the noise insulation, refer to NOISE INSULATION OVERVIEW .

-- Remove the bolts -arrows-.

Fig 1: Identifying Air Guide Pipe

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-- Disconnect the air guide pipe by lifting the clamps -2- and opening the hose clamp -3-.

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

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

-- Remove the upper coolant pipe, refer to UPPER COOLANT PIPES .

-- Remove the ignition coils, refer to IGNITION COILS WITH POWER OUTPUT STAGES -N70-, -N127-, -N291- AND -N292- .

-- Remove bolts -1, 2 and 3-. Carefully swing coolant line backward slightly.

Fig 2: Identifying Bolts

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CAUTION:

Danger of causing damage to the coolant line.

Do not change the shape of the coolant line.

-- Disconnect the connector -1- from the EVAP Canister Purge Regulator Valve 1 -N80-.

Fig 3: Connector And EVAP Canister Purge Regulator Valve 1 -N80

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-- Press the release button on the crankcase ventilation hose -2- and remove the hose.

-- Remove the bolts -arrows- and the crankcase ventilation.

-- Remove the regulator valve in the direction of the -arrow- using the Assembly Tool T10352/2.

Fig 4: Identifying Assembly Tool T10352/2

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CAUTION:

The regulator valve has left-hand threads.

-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 5: Identifying Bolts

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-- Turn the vibration damper with the Counterhold - Vibration Damper T10355 to the "TDC point".

Fig 6: Identifying Vibration Damper With Counterhold - Vibration Damper T10355

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The markings -1- on the camshaft chain sprockets must be opposite the markings -2- and -3-.
The notch on the vibration damper and the marking on the lower cover for timing chain -arrow- must be opposite one another.

-- Mark the camshaft timing chain and the cylinder head -arrows- to match the marking on the chain sprockets -1- with a waterproof marker.

Fig 7: Identifying Chain Sprockets

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-- In addition, mark the camshaft timing chain to the camshaft timing chain guide rail -2- with a permanent marker.

-- Remove the plug -arrow-.

Fig 8: Identifying Plug

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-- Remove the bolts -arrows-.

Fig 9: Identifying Bolts

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-- Install the Chain Tensioner Lever T40243 in the direction of the -arrows-.

Fig 10: Identifying Version 2

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NOTE:

A second technician is needed for the following steps.

-- Press the chain tensioner locking ring -1- together and hold it.

-- Slowly press and hold the Chain Tensioner Lever T40243 in the -direction of arrow-.

-- Secure the chain tensioner with the Tensioner Locking Tool T40267.

Fig 11: Securing Chain Tensioner

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-- Remove the Chain Tensioner Lever T40243.

-- Bolt the Camshaft Locks T40271/2 to the cylinder head and push the chain sprocket splines in the direction of -arrow 2-. If necessary, turn the intake camshaft with an Adapter T40266 in the direction of -arrow 1-.

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

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-- Remove the bolt -1- and guide the tensioning rail -2- downward.

Fig 13: Move Tensioning Rail Up And Install Bolt

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-- Install the Camshaft Locks T40271/1 on the cylinder head.

Fig 14: Identifying Camshaft Clamp T40271/1

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-- Turn the exhaust camshaft with the Adapter T40266 in the direction of - arrow 1- and slide the Camshaft Locks T40271/1 in the chain sprocket splines in the direction of -arrow 2-.

-- Mark the camshaft sprocket to the Camshaft Locks T40271/1 and the Camshaft Locks T40271/2 -arrow-.

Fig 15: Mark The Camshaft Sprocket

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-- Remove the upper guide rail -1- by unlocking the latch with a screwdriver and pushing the guide rail forward.

-- Remove camshaft timing chain from chain sprockets.

CAUTION:

Risk of damaging valves and piston crowns.

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.

-- Turn the vibration damper in the opposite direction of the engine rotation out of "TDC".

-- 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 bring the camshaft into the rest position.

Fig 16: Identifying Adapter T40266 And Intake Camshaft

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-- 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 bring the camshaft into the rest position.

Fig 17: Identifying Camshaft Locating Tool T40271/1

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

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

-- Remove the cylinder head cover bolts in sequence -1- through -6-.

Fig 18: Loosening Cylinder Head Cover

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-- Guide the cylinder head cover under the ventilation hose.

-- Remove the camshafts.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.