Camshaft: Service and Repair

Camshaft, removing and installing
(with cylinder head installed)

Removing

Installing





Special tools, testers and auxiliary items required
^ Counter support 3415
^ Torque wrench V.A.G1331
^ Torque wrench V.A.G1332
^ Sealant D 454 300 A2

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





- Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft pulley must align with arrow on toothed belt guard - arrows -.
- Loosen tensioning roller and remove toothed belt from camshaft pulley.





- Turn crankshaft back slightly.
- Remove camshaft pulley. When loosening bolt, hold camshaft pulley with counter support 3415 (remove bolts - arrows - beforehand).
- Remove woodruff key from camshaft.
- Remove intake manifold upper part.

Note:
^ Seal the intake ports with a clean cloth.

- Remove cylinder head cover.
- First remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally.

Installing

Condition
^ Pistons must not be positioned at TDC.

Note:
^ When installing the camshaft No. 1 cylinder cam lobes must point upward.





^ When installing bearing caps observe center offset of holes. Before installing the camshaft, fit the bearing caps and determine installation position.

- Oil camshaft contact surfaces.
- Set camshaft in place.
- Tighten bearing caps 2 and 4, using alternate and diagonal sequence, to 20 Nm.
- Lightly coat bearing cap 1 contact surface with sealant D 454 300 A2.
- Install bearing caps 3, 1 and 5 and also tighten to 20 Nm.
- Install woodruff key in camshaft.





- Install camshaft pulley. When tightening bolt, hold camshaft pulley with counter support 3415.
- Tightening torque: 100 Nm

Note:
^ When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

The rest of the assembly is basically a reverse of the disassembly sequence.
- Install toothed belt and tension.

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