Camshaft: Service and Repair

Camshaft, removing and installing

Special tools, equipment, testers, measuring instruments and auxiliary items required





^ 3415 Counter support
^ VAG1331 Torque wrench (5...50 Nm)
^ VAG1332 Torque wrench (40...200 Nm)
^ AMV 174 004 01 Sealant

Removing
^ Remove engine cover.
^ Remove intake manifold upper part.

Note: Seal the intake ports in the intake manifold lower section with clean cloths.

^ Remove toothed belt guard, upper part.





^ Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft.
Mark on camshaft sprocket must align with arrow on toothed belt guard.
^ Release tensioning roller and take toothed belt off camshaft pulley.
^ Turn crankshaft back slightly.





^ Remove camshaft pulley. To loosen camshaft pulley securing bolt, hold pulley with counter support 3415
^ Remove woodruff key from camshaft.
^ Remove cylinder head cover.
^ First remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally.

Installing
Requirements
^ Pistons must not be positioned at TDC.

Note:
^ When installing the camshaft, the cam lobes for cylinder 1 must face upward.





^ When installing the bearing cap note offset. Before installing camshaft fit bearing caps and determine installed position.

Work sequence
^ Oil running surfaces on camshaft.
^ Install camshaft.
^ Tighten bearing caps 2 and 4 alternately and diagonally to 20 Nm.
^ Coat contact surfaces of bearing cap 1 lightly with sealing compound AMV 174 004 01.
^ Install bearing caps 3, 1 and 5 and also tighten to20 Nm.
^ Insert woodruff key in camshaft.





^ Install camshaft pulley. To tighten securing bolt counter support camshaft pulley with 3415.
Tightening torque: 100 Nm

Note: When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.

The rest of the assembly is basically in reverse order to the disassembly sequence.
Installing toothed belt and adjusting timing.

Note: When new lifters have been installed the engine must not be started for about 30 minutes. The hydraulic compensation elements must settle (otherwise valves will strike pistons).