Camshaft, Removing And Installing: Installing

WARNING: This page is about a different car, the 2017 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Sealing surfaces must be completely free of oil and grease.

Pay attention that all roller rocker levers rest on the valve stem ends.

-- If the crankshaft was turned in the meantime, bring the piston for cylinder 1 to the top dead center position and then turn the crankshaft back again slightly.

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

-- Sealing surfaces must be free of oil and grease.

-- Lubricate the running surfaces of both camshafts.

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

Fig 1: Identifying Intake Camshaft And Cylinder Head

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-- Insert the exhaust camshaft -1- in the cylinder head cover. Turn the cam lobes of cylinder 4 -arrows- upward.

Fig 2: Identifying Exhaust Camshaft And Cylinder Head Cover

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-- Turn the intake camshaft -1- and the exhaust camshaft -2- until the markings -arrows- are in the -position shown-.

Fig 3: Identifying Intake Camshaft And Exhaust Camshaft

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-- The cams of the intake camshaft -1- and the exhaust camshaft -2- must point upward as shown -arrows-.

Fig 4: Identifying Intake Camshaft And Exhaust Camshaft

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

Fig 5: Identifying Sealant On Clean Sealing Surface Of Cylinder Head Cover

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Sealant bead thickness: 2 to 3 mm.

-- Mount the cylinder head cover on the cylinder head.

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

Fig 6: Identifying Cylinder Head Cover

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-- Replace the cylinder head cover bolts.

-- Tighten the bolts in several steps. Tightening sequence Figure.

NOTE:

Pay attention that the cylinder head cover is not tilted.

-- Turn the intake camshaft with the : T40266 in direction of -arrow A- until the markings -1 and 2- align. Push the : T40271/2 in the chain sprocket splines in direction of -arrow B-.

Fig 7: Identifying Intake Camshaft With Adapter T40266

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-- Turn the exhaust camshaft using the : T10172A in direction of -arrow A- until the markings -1 and 2- align. Slide the : T40271/1 into the chain sprocket splines in direction of -arrow B-. The mark -2- is offset slightly to the right.

Fig 8: Identifying Camshaft Lock T40271/1

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-- Turn the crankshaft on the hex fitting to the "TDC point". In the "TDC point" flat area -1- is upward.

Fig 9: Identifying Assembly Tool - Turning Over Tool T10531/3

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Install the Camshaft Timing Chain

Fig 10: Camshaft Timing Chain And Camshaft Sprocket

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-- Engage the camshaft timing chain with the painted links -arrows- on the camshaft pins.

-- Place the camshaft timing chain on the intake camshaft, exhaust camshaft and the crankshaft. Position the painted chain links -arrows- on the markings on the chain sprockets.

Fig 11: Camshaft Timing Chain On Intake Camshaft

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-- Install the guide rail -2- and tighten the bolts -1-.

Fig 12: Identifying Bolts And Glide Rail

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-- Install the upper glide rail -1-.

Fig 13: Identifying Guide Rail

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A second technician is necessary for the following step.

Fig 14: Identifying Counterhold - Kit - Multiple Use T10172

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I - Turn the exhaust camshaft with the : T10172 slightly in the direction of the -arrow A- and push the : T40271/1 out of the chain sprocket splines in the direction of the -arrow B-.

II - Release the camshaft in the direction of -arrow C-, until the timing chain touches the glide rail -1-. Hold the camshaft in this position, install the tensioning rail -2- and tighten the bolts -3-. Release the camshaft.

-- Turn the intake camshaft with the : T40266 in direction of -arrow 1- until the : T40271/2 can be pushed out of the chain sprocket splines in direction of -arrow 2-. Release the camshaft.

Fig 15: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

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-- Remove the : T40271/1 and : T40271/2 .

-- Install the bolts -arrows- and tighten them. Tightening specification -Item ) OVERVIEW - CYLINDER HEAD - List Item: Bolt.

Fig 16: Identifying Bolts

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-- Coat the holes -arrows- with engine oil.

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NOTE:

Adapter sleeve -1- is not present on every bearing bracket.

Vehicles without Adapter Sleeve

-- Attach the bearing mount. Do not tilt it when doing this. Hand-tighten the bolts -arrows-.

Fig 17: Bearing Bracket Bolts

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Vehicles with Adapter Sleeve

-- Attach the bearing mount. Do not tilt it when doing this. Tighten the bolts -1 to 6- hand-tight.

Fig 18: Bearing Bracket - Tightening Sequence

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-- If an adapter sleeve is installed, this will be moved with the bolt -1- in the cylinder head.

Continuation for All Vehicles

-- Remove the : T40267 .

Fig 19: Securing Chain Tensioner With T40267

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-- Tighten the bearing bracket bolts -arrows-. Tightening specification. Refer to OVERVIEW - CAMSHAFT TIMING CHAINS .

Fig 20: Bearing Bracket Bolts

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-- Install the chain tensioner -2-. The wire clip must come in to contact with the oil pan upper section opening -arrow-. Tighten the bolt -1- and remove the : T40011 .

Fig 21: Identifying Chain Tensioner

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-- Check the adjustment. The painted chain links -arrows- must line up with the markings on the chain sprockets.

Fig 22: Identifying Painted Chain Links Must Line Up With Markings On Chain Sprockets

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-- Install the control valve. Refer to Camshaft Adjustment Valve 1 -N205-, REMOVING AND INSTALLING .

-- Let the engine turn a second time in the direction of engine rotation.

NOTE:

Due to the ratio, the painted chain links no longer match up after the engine has been turned.

-- Remove the : T10531/4 and remove the : T10531/3 .

Fig 23: Identifying Assembly Tool - Turning Over Tool T10531/3

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-- Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

NOTE:

Tighten the bolts -1 and 4- with -4- an additional turn after installing the vibration damper. The bolts must be removed again to install the vibration damper.

Fig 24: Identifying 8 Bolt Timing Chain Lower Cover Bolt Tightening Sequence

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-- Install the vibration damper. Refer to VIBRATION DAMPER, REMOVING AND INSTALLING .

-- Install the upper timing chain cover. Refer to TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the vacuum pump. Refer to VACUUM PUMP, REMOVING AND INSTALLING .

-- Install the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

Installation is performed in reverse order of removal, while noting the following:

-- 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