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 Fitting Tool (T40095)

• Camshaft Fitting Tool (T40096)

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

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Silicone Adhesive Sealant (D 176 501 A1)

Removing

Risk of damaging valves and piston heads after working on valve train.

• The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.

• To ensure valves do not strike pistons when starting, carefully rotate the crankshaft at least 2 turns.

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the fuel filter housing.

- Remove the toothed belt from the camshaft sprocket and high pressure pump. refer to => [ Toothed Belt ] Toothed Belt.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

- Remove the camshaft sprocket bolts - 1 -.






- Remove the camshaft sprocket from the hub.

- Counter hold the hub with the camshaft gear counter-holder (T10051) and loosen the hub bolt- 1 -.






- Remove the hub bolt approximately 2 turns.

- Attach the puller (T10052) and align it with the hub openings.






- Tighten the bolts - 1 -.

- Steadily fasten the puller - 2 - to the hub until the hub is loosened from the taper of the camshaft.

• Hold onto the puller with a 30 mm wrench.

- Remove the hub from the camshaft.

- Remove the vacuum pump. Refer to => [ Vacuum Pump ] Service and Repair.

- Remove the bearing frame bolts in sequence - 24 through 1 -.






- Remove the bearing frame.

- Carefully remove the camshaft.

Installing

• Seal the separating surfaces between the bearing frame and cylinder head with silicone adhesive sealant (D 176 501 A1).

The camshafts may only be installed using the camshaft fitting tool (T40094) as described. Otherwise the axial bearings inside the bearing frame will get permanently damaged and it will be necessary to replace the cylinder head.

- Remove any sealant still on the cylinder head and on the bearing frame with a rotating plastic brush.

Make sure that no sealant residue enters the cylinder head and bearings.

- Clean the sealing surfaces.

• The sealing surfaces must be free of oil and grease

- Oil the running surfaces of both camshafts.

Set up the camshaft fitting tool (T40094) for the camshaft as follows:

- Remove the mounts (T40094/3) , (T40094/4) and (T40094/5) from the base plate. Loosen the lower bolts.






• If the camshaft fitting tool (T40094) mounts are not marked, mark the removed mounts, for example, with numbers, to assure they can be assembled later.

- Install the mounts mounts (T40094/9) and (T40094/10) in the empty outer locations.






- Install the mount (T40094/2) in position "A" and install the mount (T40094/1) in position "F".

- Insert the intake camshaft as shown. 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.






- Secure the exhaust camshaft above the groove - arrow - with the cover (T40094/11).






- Position the tensioning tool (T40096/1) on the exhaust camshaft sprockets.

Make sure the clamping jaw marked with an arrow is on the wider sprocket.

- Tension the tensioning tool (T40096/1) with the thumb wheel 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.

- Mount the bearing frame on the camshafts.

• All the camshaft bearings must align on the camshafts.

- Position the camshaft fitting tool (T40095) as illustrated and secure the camshafts in the bearing frame.






- Remove the cover (T40094/11).

- Remove the mount (T40094/8) from the intake camshaft groove.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 2 mm).






- Apply a bead of sealant (approximately 2 to 3 mm) - arrows - on the clean sealing surfaces of the cylinder head as illustrated.

The excess sealant could get on the camshaft bearings or seal off the oil supply holes.

• Do not apply the sealant bead thicker than indicated.

• Make sure that the excess sealant does not seal off the oil supply holes - arrow - for the bearing frame.

Sealant Bead for the Bearing Frame





- Remove the camshafts with the bearing frame and the camshaft fitting tool (T40095) from the camshaft fitting tool (T40094).

- Carefully insert the camshafts and bearing frame in the cylinder head.

- Then, tighten the bearing frame bolt by hand in sequence - 1 through 24 -.






• The guide frame must be touching the entire contact surface of the cylinder head.

- Tighten the bearing frame bolts to 10 Nm in sequence - 1 through 24 -.

- Remove the camshaft fitting tool (T40095) and the tensioning tool (T40096/1).

- Replace the camshaft seal. Refer to => [ Camshaft Seal ] Service and Repair.

- Install a new sealing cap - item 7 - in the => [ Valvetrain Overview ] Service and Repair, onto the cylinder head with a suitable drift until it is flush.

Further installation is performed in the reverse order of removal, noting the following:

Risk of damaging the valves and piston heads after working on valve train.

• The engine must not be started for about 30 minutes after installing the camshafts because the hydraulic lash adjusters must seat themselves.

• To ensure the valves do not strike the pistons when starting, carefully rotate the crankshaft at least 2 revolutions.

- Place the hub on the camshaft.

- Tighten the hub bolt - 1 -. Use the camshaft gear counter-holder (T10051) to do so.






- Push the camshaft sprocket onto the hub.






• The toothed segment - arrow - of the camshaft sprocket must face upward.

- Install the bolts - 1 - into the camshaft sprocket by hand to eliminate play.

- Secure the hub with the diesel injection pump locking pin (3359).

- Install the toothed belt and adjust valve timing. 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.

- Install the fuel filter housing.

Tightening Specifications