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)

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

• The sealing surfaces on the guide frame and the cylinder head must not be reworked.

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

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

- Lock the camshafts and remove the camshaft sprockets. 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 remainder of sealant from the guide frame (out of the grooves as well) and from the cylinder head, using for example, a rotating plastic brush.

Make sure that no sealant residue enters the engine.

- Clean the sealing surfaces, they must be free of oil and grease.

- Lubricate the journal surfaces of the camshafts.

- Place the guide frame upside down on a soft surface.

- Lay 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 - in 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 installed, 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 to 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 of the guide frame - 1 through 8 -.






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 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 sealant.

- Install the guide frame to 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 shown.






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

- The sealant must bulge outward slightly, even in the area 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 the 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 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 ] Service and Repair.