Camshaft: Service and Repair

Camshafts

Special tools, testers and auxiliary items required

• Torque wrench (5-50 Nm) (VAG 1331)

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant (D 154 103 A1)

Removing

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

• Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide frame, chain sprockets of camshafts must be removed.

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

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

- Remove the (T40070).





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

- Carefully remove the camshaft and place it on a clean surface.

Installing

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

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

CAUTION!
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.

- Install the camshafts correctly into the guide frame.





• Intake camshaft with sensor wheel - 2 - points toward the Camshaft Position (CMP) sensor (G40) - 1 -.

• Camshafts must lie exactly in the axial bearings - 3 - in the guide frame.

• Seal ends - 4 and 5 - must point upward or downward, they must not point to the side under any circumstances.

- With the camshafts installed in the guide frame, hold the camshafts firmly in place and turn over and install the guide frame.

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





- Turn over the guide frame again.

- Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (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 4.0 mm

• Sealant beads must be applied according to exact specifications, otherwise 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 sealing compound.

- Install the guide frame onto the cylinder head immediately.

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

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





- After that, continue to tighten all bolts an additional 90° (1/4) further.

- Sealant must bulge outward slightly, even in the area of chain compartment - arrows -.





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

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





• If the 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 procedures. When doing this note the following:

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

• Fill with coolant. Refer to => [ Draining and Filling ] Draining and Filling.