Camshaft: Service and Repair
Camshafts
Special tools, testers and auxiliary items required
• Diesel Injection Pump Locking Pin (3359)
• Camshaft Gear Counter-Holder (T10051)
• Puller (T10052)
• Camshaft Fitting Tool (T40094)
• Camshaft Clamping Tool (T40095)
• Camshaft Tensioning Tool (T40096)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Hand Drill with Plastic Brush Attachment
• Protective Eyewear
• Silicone Adhesive Sealant (D 176 501 A1)
Removing
- Remove the toothed belt from the camshaft and the high pressure fuel pump. Refer to => [ Toothed Belt ] Toothed Belt.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Remove bolts - 1 - from the camshaft gear.
- Remove the camshaft gear from the hub.
- Counter hold the hub using the camshaft gear counter-holder (T10051) and loosen the hub bolt - 1 -.
- Loosen the bolt for the hub by approximately 2 turns.
- Position the puller (T10052) and align it to the bores in the hub.
- Tighten the bolts - 1 -.
- Tension the hub by tightening the puller (T10052) - 2 - evenly until it can be removed from the camshaft taper.
• Hold the puller (T10052) with a 30 mm wrench.
- Remove the hub from the cone of the camshaft.
- Remove the vacuum pump. Refer to => [ Vacuum Pump ] Service and Repair.
- Remove the bearing frame bolts and nuts in sequence - 24 through 1 -.
- Remove the bearing frame.
- Carefully remove the camshafts.
Installing
• Note the expiration date of the silicone adhesive sealant (D 176 501 A1).
• Seal the separating surfaces between the bearing frame and cylinder head using silicone adhesive sealant (D 176 501 A1).
• Only install the camshafts with the camshaft fitting tool (T40094) as described below. Otherwise the axial bearing in the bearing frame will be destroyed and the cylinder head will have to be replaced.
• Make sure that no sealant residue enters the cylinder head and bearings.
Wear safety glasses.
- Remove any sealant still on the cylinder head and bearing frame with a rotating plastic brush.
- Clean the sealing surfaces, they must be free of oil and grease.
- Oil the journal surfaces of camshafts.
Assemble the camshaft fitting tool (T40094) as follows:
- Remove the mounts (T40094/3) , (T40094/4) and (T40094/5) from the base plate. Loosen the threaded connections from below.
• If the camshaft fitting tool (T40094) mounts are not marked, mark the removed mounts, for example, with numbers, to assure it can be assembled later.
- Install the mounts (T40094/9) and (T40094/10) in the empty outer locations.
- Position mount (T40094/2) on location "A" and mount (T40094/1) on location "F".
- First install the intake camshaft as illustrated. Make sure the indentation - arrow - for the cylinder head bolt faces "outward".
- Position the 0.50 mm feeler gauge and slide the mount (T40094/8) into the groove on the intake camshaft.
- Install the exhaust camshaft.
- Secure the exhaust camshaft above the groove - arrow - with the cover (T40094/11).
- Mount the tensioning tool (T40096/1) on the toothed gears on the exhaust camshaft.
Make sure the clamping jaw marked with an arrow is on the wider gear.
- Tighten the tensioning tool (T40096/1) with the knurled thumb screw until the tooth faces align. Use a 13 mm open end wrench if necessary.
- Slide the intake camshaft toward the exhaust camshaft until the splines mesh.
- Position the bearing frame on the camshafts.
• All the camshaft bearings must align on the camshafts.
- Position the camshaft clamping tool (T40095) as illustrated and secure the camshafts in the bearing frame.
- Remove the cover (T40094/11).
- Remove the mount (T40094/8) from the groove in the intake camshaft.
- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 3 mm).
- Apply the silicone adhesive sealant (D 176 501 A1) to the clean sealing surface of the cylinder head as illustrated. The sealant bead must be:
• 2 to 3 mm thick
• Apply on the inner side in the area with the threaded holes
• The sealant beads must not be thicker than 2 to 3 mm or the excess sealant can enter the camshaft bearing.
- Remove the camshafts with the bearing frame and the camshaft clamping tool (T40095) from the camshaft fitting tool (T40094).
- Carefully install the camshafts and bearing frame to the cylinder head.
- First, tighten the bearing frame bolts and nuts by hand in sequence - 1 through 24 -.
• The bearing frame must be in contact with the entire contact surface of the cylinder head.
- Tighten the bearing frame bolts and nuts in sequence - 1 through 24 -.
• Tightening specifications, see - items 2 and 3 - in the => [ Valvetrain Overview ] Service and Repair.
- Remove the camshaft clamping tool (T40095) and the tensioning tool (T40096/1).
- Replace the camshaft seal. Refer to => [ Camshaft Seal ] Service and Repair.
- Drive a new cap onto the cylinder head with a suitable drift until it is flush.
The rest of the installation is performed in reverse order of removal, noting the following:
• After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic lash adjusters must seat themselves (otherwise the valves will crash into the pistons).
• After working on the valvetrain, carefully rotate the engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.
- Place the hub on the camshaft.
- Counterhold the hub with the camshaft gear counter holder (T10051) and tighten the hub bolt - 1 -.
• Tightening specification, see - item 11 - in the => [ Toothed Belt Overview ] Toothed Belt Overview.
- Push the camshaft gear onto the hub.
• The toothed segment - arrow - of the camshaft gear must face upward.
- Install the bolts - 1 - into the camshaft gear by hand to eliminate play.
- Lock the hub using the diesel injection pump locking pin (3359).
- Install and tension the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.
- Install the vacuum pump. Refer to => [ Vacuum Pump ] Service and Repair.
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.