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)

Removing

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

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

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

- Lock the camshafts and remove the camshaft sprocket and adjuster. Refer to => [ Valve Timing, Adjusting ] Adjustments.

- Remove the (T40070).





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

- Carefully remove the camshaft upward 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.





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

• 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 with the camshafts installed, hold the camshafts firmly in place in the guide frame while doing this. Install the guide frame and camshafts.

- 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 onto the camshafts and tighten the bolts to 20 Nm.





- Remove the guide frame and turn it over again.

- Cut the 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 mm

• Grooves - 6 through 8 -: approximately 4 mm

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

• Install 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 working from the inside 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) turn.

- The sealant must squeeze out slightly, even in the chain compartment area - 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 anew up to the marking.

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

• Remove the (T40069) from the rear of the cylinder block and install the locking bolt. Tighten the bolt to 45 Nm.

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