Camshaft: Service and Repair

Camshaft, removing and installing

(with cylinder head installed)

Special tools, testers and auxiliary items required




- Retainer 3036
- Chain tensioner retainer 3366
- VAG1331 Torque wrench (5 to 50 Nm)
- VAG1332 Torque wrench (40 to 200 Nm)
- Sealing compound AMV 174 004 01
- Sealing compound D 454 300 A2

Removing

- Remove engine cover.
- Remove upper toothed belt guard.






- Set camshaft sprocket to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft sprocket must align with mark on cylinder head cover.
- Remove cylinder head cover.
- Take toothed belt off camshaft toothed belt sprocket.
- Turn crankshaft back slightly.
- Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036.
- Remove woodruff key from camshaft.
- Remove camshaft position sensor housing.
- Remove washer and hood for camshaft position sensor.





- Clean drive chain and camshaft chain sprocket in area of arrows on bearing caps and mark installation position with a colored mark.

- The distance between the two arrows/paint marks is equivalent to 16 drive chain rollers.





Note: Do not mark chain with a punched mark, notch or similar.
The distance between both arrows or the colored marks equals 16 rollers on the drive chain.






- Secure chain tensioner with retainer for chain tensioner 3366.

Note: Hydraulic chain tensioner can be damaged if chain tensioner retainer is overtightened.






- Remove intake and exhaust camshafts 3rd and 5th bearing caps.
- Remove double bearing cap.
- Remove both bearing caps at chain sprockets on intake and exhaust camshafts.
- Remove chain tensioner securing bolts.
- Remove intake and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence.
- Remove chain tensioner for intake and exhaust camshafts and retainer for chain tensioner 3366.

Installing

Note: When installing the camshafts the cam lobes for cylinder 1 must point upward.
When installing the bearing caps, ensure that the cap markings can be read from the inlet side of the cylinder head.

- If reusing old drive chain, install drive chain onto both camshafts relevant to colored markings.






Note: When using a new timing chain, the distance between notches -A- and -B- at the camshaft equals 16 rollers on the drive chain.
The figure shows where on the sprockets the 1st and 16th rollers must be placed.
Notch -A- is slightly offset toward inside to chain roller 1.






- Replace rubber/metal seal for camshaft adjuster or chain tensioner and lightly coat hatched area with sealant D 454 300 A2.
- Insert camshaft adjuster or chain tensioner between drive chain.
- Oil running surfaces of both camshafts.
- Insert camshafts with drive chain and camshaft adjuster/chain tensioner in cylinder head.
- Tighten camshaft adjuster or chain tensioner to 10 Nm (take note of dowel sleeves).





- Tighten intake and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence to 10 Nm (take note of dowel sleeves).





- Install both bearing caps at chain sprockets for intake and exhaust camshafts. Check camshafts are positioned correctly and tighten bearing cap to 10 Nm (remember dowel sleeves).
- Remove retainer for chain tensioner 3366.





- Coat hatched area of double bearing cap lightly with sealant D 454 300 A2, install and tighten to 10 Nm (remember dowel sleeves).
- Install remaining bearing caps and tighten to 10 Nm (remember dowel sleeves).





- Observe installation position.
- Install camshaft sprocket. Bevelled edge of camshaft faces outward -arrows- and TDC Cyl. 1 is visible at front
- Tighten securing bolt to 65 Nm (use counter-hold tool 3036).





- Recheck position of camshafts relative to one another -arrows-

The rest of the assembly is basically a reverse of the disassembling sequence.
Installing toothed belt and adjusting timing. Procedures

Note: After installing new lifters the engine must not be started for approximately 30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).