Removal and Replacement

Camshafts, removing and installing
(with cylinder head installed)





Special tools, testers and auxiliary items required
^ Counter-holder tool 3036
^ Holder for chain tensioner 3366
^ Torque wrench V.A.G 1332
^ Sealant D 454 300 A2

Removing
- Bring lock carrier into service position. [1][2]Procedures
- Remove upper toothed belt guard.





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





- Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with paint.

Note:
^ Do not mark chain with a center punch, metal file, or any similar means.
^ The distance between both arrows or colored markings consists of 16 rollers of the drive chain.





- Secure crankshaft adjuster using bracket for chain adjustment 3366.

Note: If the chain tensioner retainer is fastened too tightly, the camshaft adjuster can 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 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 bracket for chain adjustment 3366.

Installing

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

- Place drive chain onto both camshaft sprockets according to color markings.





- Replace rubber/metal seal for camshaft adjuster or chain tensioner and coat hatched surface with thin coat of sealant D 454 300 A2.
- Push camshaft adjuster in between drive chain.
- Lubricate journal surfaces of both camshafts with clean engine oil.
- 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 and tighten to 10 Nm (pay attention to bushing).





- Install both bearing caps on chain gears of intake and exhaust camshafts. Check camshaft for proper adjustment and tighten bearing cap to 10 Nm (pay attention to alignment bushing).
- Remove bracket for chain adjustment 3366.





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





- Check setting of camshafts to each other.

The rest of assembly is basically a reverse of disassembling sequence.

Note: After installing camshafts, do not operate the starter or allow the crankshaft to turn for at least 30 minutes. The hydraulic valve lifters need time to compress, otherwise valves may strike the pistons.