Camshaft: Service and Repair

Camshaft

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Sealant (D 154 103 A1)

Removing

• The sealing surfaces on the bottom of the guide frame and on the top of the cylinder head must not be reworked.

• The camshaft bearings are integrated in the cylinder head and in the guide frame. Before removing the guide frame, the adjuster and sprocket on the camshafts must be removed.

• If the guide frame was loosened, the sealing plugs must be replaced.

- Secure the camshafts and remove the adjuster and sprocket from the camshafts. Refer to => [ Valve Timing, Adjusting ] Valve Timing, Adjusting.

- Then, remove the camshaft clamp (T40070).






- Remove the guide frame bolts evenly working from the outside toward the inside and remove the guide frame.

- Carefully remove the camshafts upward and place them on a clean surface.

Installing


To prevent injuries from shavings, wear protective goggles and protective clothing.

- Remove the remainder of the sealant from the guide frame (out of the grooves as well) and from the cylinder head, using for example, a rotating plastic brush.


Make sure that no sealant residue enters the engine.

- Clean the sealing surfaces, they must be free of oil and grease.

- Oil the journal surfaces of the camshafts.

- Place the guide frame on a soft surface.

- Insert the camshafts correctly into the guide frame.






• The intake camshaft with the sensor wheel - 2 - faces toward the camshaft position sensor (G40) - 1 -.

• The camshafts must lie exactly in the axial bearings - 3 - of the guide frame.

• The ends of the seals - 4 and 5 - must face up or down. They must not face to the side.

- Turn over the guide frame slightly with the camshafts installed, hold the camshafts firmly in place in the guide frame while doing this.

- Rotate the camshafts until the threaded holes - arrows - point upward.






- Check whether the camshafts still lie exactly in the axial bearings of the guide frame.

- Install the camshaft clamp (T40070) as shown to the camshafts and tighten the bolts to 20 Nm.






- Turn over the guide frame again.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).






- Lightly apply an even bead of sealant into the clean grooves of the guide frame - 1 through 8 -.






Width of sealant bead:

• Grooves - 1 through 5 -: approximately 3.0 mm

• Grooves - 6 through 8 -: approximately 4 mm

• The sealant beads must be applied according to exact specifications, otherwise the excess sealant could get into the camshaft bearings.

• Installing and securing the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces.

• Note the expiration date of the sealant.

- Place the guide frame onto the cylinder head immediately.

- Gently tighten the bolts working from the inside toward the outside in several stages.

- Then, tighten the bolts to 8 Nm in the sequence indicated.






- After that, tighten all the bolts an additional 90° (1/4) turn.

- The sealant must squeeze out slightly, even in the chain compartment area - arrows -.






- Wipe off the excess sealant on the sealing surface facing the timing chain cover.

- Carefully press in the sealing plugs - A - until they reach the end of the chamfer - arrows -.






• If a sealing plug was pressed in too far, it must be pressed through and pressed in again up to the mark.

The rest of the installation follows the reverse of the removal procedure. Note the following:

• Remove the locking pin (T40069) from the rear of the cylinder block and install the locking bolt (30 Nm).

• Fill the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.