Camshaft: Service and Repair

Camshaft, removing and installing





Engine codes AEG, AVH AZG, BEV

Special tools and equipment
^ 3415 Counter support
^ V.A.G 1331 Torque wrench (5 to 50 Nm)
^ V.A.G 1332 Torque wrench (40 to 200 Nm)
^ AM 174 004 01 Sealing compound

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

Note: Seal the intake ports in the intake manifold lower part with a clean cloth.

- 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.
- Loosen tensioning roller and remove toothed belt from camshaft pulley.
- Turn crankshaft back slightly.





- Take camshaft pulley off. When loosening bolt hold camshaft pulley with counterhold 3415.
- Remove woodruff key from camshaft.
- Remove cylinder head cover.
- First remove bearing caps 5, 1 and 3. Tighten bearing caps 2 and 4 alternate and diagonally.

Installing

Requirements
^ Pistons must not be positioned at TDC.

Note:
^ When installing the camshaft, the cam lobes for cylinder 1 must be facing up.





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

Work sequence
- Oil contact 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 to 20 Nm.
- Install woodruff key in camshaft.





- Take camshaft pulley off. When loosening bolt hold camshaft pulley with counterhold 3415.
Tightening torque: 100 Nm

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

Further installation is the reverse of removal.

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

Engine code BBW

Special tools and equipment





^ V.A.G 1331 Torque wrench (5 to 50 Nm)





^ V.A.G 1332 Torque wrench (40 to 200 Nm)
^ AMV 174 004 01 Sealant

Removing
- Remove camshaft sprocket.

Note: - Remove toothed belt only from camshaft sprocket.

- 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 be facing up.





^ When installing the bearing cap note offset. Before installing camshaft 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 to 20 Nm.
- Install toothed belt.

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