Camshaft, Removing and Installing

Camshaft, removing and installing
(with cylinder head installed)

Special tools and equipment




- 3036 retainer
- 3366 bracket for chain adjustment
- VAG1332 torque wrench (40 to 200 Nm)
- Sealant D 454 300 A2

Removing
- Bring the lock carrier into service position Lock Carrier And Front Bumper Reinforcement, Moving to Service Position
- Remove upper portion of toothed belt guard.






- Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must be flush with marking on cylinder head cover.
- Remove cylinder head cover.
- Loosen tensioner and lift toothed belt from camshaft gear.
- Turn crankshaft back slightly.
- Remove camshaft gear. To loosen bolt, counterhold camshaft gear using 3036 retainer.
- Remove Hall sensor housing.
- Remove washer and cover for Hall sensor.






- Clean camshaft drive chain and camshaft chain gears opposite both arrows on bearing caps. Mark installed position with paint.






Note: Do not mark chain using punch, notch or similar.
The distance between the two arrows/paint marks is equivalent to 16 drive chain rollers.





- Secure crankshaft adjuster using 3366 bracket for chain adjustment.

Note: If chain tensioner bracket is tightened too much, camshaft adjuster may be damaged.





- First remove bearing caps 3 and 5 from intake and exhaust camshafts.
- Remove double bearing cap.
- Remove both bearing caps from chain gears on intake and exhaust camshafts.
- Remove mounting bolts for camshaft adjuster.
- Alternating in diagonal sequence, loosen bearing caps 2 and 4 of intake and exhaust camshafts and remove.
- Remove intake and exhaust camshafts along with camshaft position adjuster and 3366 bracket for chain adjustment.

Installing

Note: When installing camshafts, cams lobes for cylinder 1 must point upward.
When installing bearing caps, verify marking on cap is readable from intake side of 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.

Caution:
- The number of rollers given only serves an aid when positioning the chain on the camshaft.
- When positioning the camshafts (with chain) in the cylinder head, make sure the arrows on the bearing caps and the notches on the camshafts align.





- Replace rubber/metal seal for camshaft adjuster or chain tensioner and coat hatched surface with thin coat of "D 454 300 A2" sealant.
- Push camshaft adjuster in between drive chain.
- Oil running surfaces of both camshafts.
- Place camshafts with drive chain and camshaft adjuster into cylinder head.
- Tighten camshaft adjuster to 10 Nm (pay attention to bushing).






- Alternating in diagonal sequence, tighten bearing caps 2 and 4 of intake and exhaust camshafts slightly and tighten to 10 Nm (pay attention to bushing).





- Install both bearing caps from chain gears on intake and exhaust camshafts. Check camshaft for proper adjustment and tighten bearing cap to 10 Nm (pay attention to bushing).





- The two camshaft markings must align with both arrows on bearing caps -arrows-.
- Remove 3366 bracket-tensioner.





- Coat hatched surface of double bearing cap lightly using "D 454 300 A2" sealant, install and tighten to 10 Nm (pay attention to bushing).
- Install remaining bearing cap and tighten to 10 Nm (pay attention to bushing).





- 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 two camshaft markings must align with both arrows on bearing caps -arrows-.

The rest of the installation follows the reverse of the removal procedures.
Installing toothed belt and adjusting timing. Procedures

Notes: After camshafts, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons).