Camshaft: Service and Repair

Camshafts

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)

Note the following whenever working inside the engine compartment due to limited space:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

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 or in the guide frame. Before removing the guide frame, the camshaft sprockets must be removed.

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

- Lock the camshafts and remove the sprockets from the camshafts. Refer to => [ Valve Timing, Adjusting ] Adjustments.

- 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 any remaining sealant from the guide frame (out of the grooves as well) and from the cylinder head, using for example, 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 upside down 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 seals - 4 and 5 - must point upward or downward, they must not point to the side under any circumstances.

- Turn over the guide frame with the camshafts inserted, 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 in the guide frame.

- Install the camshaft clamp (T40070) as shown, onto 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 - 1 through 8 - of the guide frame.






Width of the sealant bead:

• Grooves - 1 through 5 -: approximately 3.0 mm

• Grooves - 6 through 8 -: approximately 4.0 mm

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

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

• Note the expiration date of the sealant.

- Install the guide frame onto the cylinder head immediately.

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

- Then, tighten the bolts to 8 Nm in sequence - 1 through 7 -.






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

- The sealant must bulge outward slightly, even in the areas of the chain compartment - arrows -.






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

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






• If the sealing plugs were pressed in too far, they must be pressed through and pressed in again up to the end of the chamfer.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

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

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