Removal And Installation: Camshaft: Installing

WARNING: This page is about a different car, the 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: Seal the separating surfaces between the bearing frame and cylinder head with Silicone Adhesive Sealant D 176 501 A1.

CAUTION: The camshafts may only be installed using the Camshaft Fitting Tool T40094 as described. Otherwise the axial bearings inside the bearing frame will get permanently damaged and it will be necessary to replace the cylinder head.

-- Remove any sealant still on the cylinder head and on the bearing frame with a rotating plastic brush.

CAUTION: Make sure that no sealant residue enters the cylinder head and bearings.

-- Clean the sealing surfaces.

Sealing surfaces must be free of oil and grease

-- Oil running surfaces of both camshafts.

Set up the Camshaft Fitting Tool T40094 for camshaft as follows:

-- Remove mounts -T40094/3-, T40094/4 and -T40094/5- from the base plate. Loosen the lower bolt.

Fig 1: Identifying Mounts T40094/1 To T40094/8

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NOTE: If the Camshaft Insertion Tool T40094 mounts are not marked, mark the removed mounts, for example, with numbers, to assure it can be assembled later.

-- Install the mounts -T40094/9- and -T40094/10- in the empty outer locations.

Fig 2: Identifying Mounts T40094/1, T40094/2, T40094/9, T40094/10 and T40094/11

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-- Install mount -T40094/2- in the position "A" and install the mount -T40094/1- in the position "F".

-- Insert the intake camshaft as shown. Make sure the indentation -arrow- for the cylinder head bolt faces outward.

-- Position the 0.50 mm feeler gauge and slide the mount -T40094/8- into the groove on the intake camshaft.

Fig 3: Identifying 0.50 mm Feeler Gauge

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-- Secure the exhaust camshaft above the groove -arrow- with the -cover T40094/11-.

Fig 4: Identifying Cover T40094/11

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-- Position the Tensioning Tool T40096/1 on the exhaust camshaft sprockets.

CAUTION: Make sure the clamping jaw marked with an arrow is on the wider sprocket.

-- Tension the Tensioning Tool T40096/1 with the thumb wheel until the tooth faces align. Use a 13 mm open-end wrench if necessary.

Fig 5: Identifying Tensioning Tool T40096/1

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-- Slide the intake camshaft toward the exhaust camshaft until the splines mesh.

-- Mount the bearing frame on the camshafts.

All the camshaft bearings must lie on the camshafts.

-- Position the Clamping Tool T40095 as shown and secure the camshafts in the bearing frame.

Fig 6: Identifying Camshaft Clamping Tool T40095

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-- Remove the Cover T40094/11.

-- Remove the Mounts T40094/8 from the intake camshaft groove.

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).

Fig 7: Cutting Tube Nozzle At Front Marking (Nozzle Diameter Approx. 2 mm)

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-- Apply a bead of sealant (approximately 2 to 3 mm side) -arrows- on the clean sealing surfaces of the cylinder head as shown.

CAUTION:

Excess sealant could get on the camshaft bearings or seal off the oil supply holes.

Do not apply sealant beads thicker than indicated.
Make sure that excess sealant does not seal off the oil supply holes -arrow- for the bearing frame.

Fig 8: Identifying Bearing Frame Sealant Position

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-- Remove the camshafts with the bearing frame and the Clamping Tool T40095 from the Camshaft Insertion Tool T40094.

-- Carefully insert the camshafts and bearing frame in the cylinder head.

-- Then tighten the bearing frame screws by hand in the sequence -1- to -24-.

Fig 9: Identifying Bearing Frame Bolts/Nuts Tightening Sequence

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The guide frame must be touching the entire contact surface of the cylinder head.

-- Tighten the bearing frame bolts to 10 Nm in sequence -1- through -24-.

-- Remove the Clamping Tool T40095 and the Tensioning Tool T40096/1.

-- Replace the camshaft seal. Refer to CAMSHAFT SEAL .

-- Install a new sealing cover, -item 7-, onto the cylinder head with a suitable drift until it is flush.

Install in reverse order of removal. Note the following:

CAUTION:

Risk of damaging valves and piston heads after working on valve train.

The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.
To ensure valves do not strike pistons when starting, carefully rotate the crankshaft at least 2 turns.

-- Place the hub on the camshaft.

-- Tighten the hub bolt -1-. Use Counterholder T10051 to do so.

Fig 10: Identifying Camshaft Gear Counter-Hold T10051

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-- Push the camshaft sprocket onto the hub.

Fig 11: Identifying Camshaft Pulley Bolts

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NOTE: The toothed segment -arrow- of the camshaft sprocket must face upward.

-- Install the bolts -1- into the camshaft sprocket by hand to eliminate play.

-- Secure the hub with the Locking Pin 3359.

-- Install toothed belt and adjust valve timing. Refer to Installing .

-- Install the vacuum pump. Refer to Installing .

-- Install the cylinder head cover. Refer to Installing .

-- Install the fuel filter. Refer to Description and Operation .