Removal And Installation: Camshaft: Installing

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

WARNING: To prevent injuries from shavings, wear protective goggles and protective clothing.

-- Remove remainder of sealant from guide frame (out of grooves as well) and from cylinder head for example using a rotating plastic brush.

CAUTION: Make sure that no sealant residue enters the engine.

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

-- Oil journal surfaces of camshafts.

-- Place guide frame on a soft surface.

-- Insert camshafts correctly into guide frame.

Fig 1: Identifying Camshafts Inserted Correctly Into Guide Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The intake camshaft with the sensor wheel -2- faces toward the Camshaft Position Sensor -G40- -1-.
Camshafts must lie exactly in the axial bearings -3- of guide frame.
Sealing ring ends -4 and 5- must point upward or downward, they must not point to the side under any circumstances.

-- Turn around guide frame with inserted camshafts slightly, hold camshafts firmly in place in guide frame while doing this.

-- Rotate the camshafts until the threaded hole -arrows- face upward.

Fig 2: Identifying Threaded Holes

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-- Check whether camshafts still lie exactly in axial bearings of guide frame.

-- Install the Camshaft Clamp T40070 on the camshafts as shown, and then tighten the bolts to 20 Nm.

Fig 3: Identifying Camshaft Clamp T40070 Installed On To Camshafts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn around guide frame again.

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1 mm).

Fig 4: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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-- Lightly apply an even bead of sealant into the clean grooves of the guide frame -1 to 8-.

Fig 5: Identifying Bead Of Sealant Lightly Applied Into Clean Grooves Of Guide Frame

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Width of sealant bead:

Grooves -1 through 5- : approximately 3.0 mm
Grooves -6 through 8- : approximately 4.0 mm

NOTE:

Sealant beads must be applied according to exact specifications, otherwise excess sealant could get into the camshaft bearings.

Attaching and bolting the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces.

Note the expiration date of the sealing compound.

-- Attach guide frame on cylinder head immediately.

-- Gently tighten bolts from inside working toward outside in several stages.

-- Then tighten bolts to 8 Nm in the sequence indicated.

Fig 6: Identifying Tightening Bolts Sequence

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-- Tighten all the bolts 90° (¹ /₄ turn) further.

-- The sealant must be squeezed out slightly, even in the area of the chain chamber -arrows-.

Fig 7: Identifying Chain Compartment Sealant Locations

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-- Wipe off any sealing compound on the timing chain cover sealing surface.

-- Carefully press in the sealing plugs -A- up to the end of the chamfer -arrows-.

Fig 8: Identifying Sealing Plugs

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NOTE: If sealing plug was pressed in too far, it must be pressed through and pressed in again up to the marking.

The rest of the installation follows the reverse of the removal procedures. Note the following:

-- Remove the Crankshaft Locking Pin T40069 from the back of the cylinder block and install the bolt.

-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .