Camshaft: Service and Repair

Camshaft

Special tools, testers and auxiliary items required

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

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

• Camshaft Bar (T10068 A)

• Counterhold Tool (T10172)

• Adjustment Tool (T10363)

• Silicone Adhesive Sealant (D 176 501 A1)

Removing

- Remove the air filter housing. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

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

- Remove both camshaft adjusters. Refer to => [ Camshaft Adjuster ] Camshaft Adjuster.

- Remove the control housing bolts - arrows - from the control housing and pull the control housing off of the cylinder head.






- Place the camshaft timing chain to the side.

Intake Camshaft (- A -)






- First, remove bearing caps 1 and 13.

- Remove bearing caps 3 and 11.

- Remove bearing cap 7.

- Loosen and remove bearing caps 5 and 9 alternately and in a diagonal sequence.

Exhaust Camshaft (- B -)






- First, remove bearing caps 2 and 14.

- Remove bearing caps 4 and 12.

- Remove bearing cap 8.

- Loosen bearing caps 6 and 10 alternately and in a diagonal sequence.

Continuation for Both Camshafts:

- Carefully remove the camshafts and place them on a clean surface.

- Remove the roller rocker arms together with the hydraulic lash adjusters and then lay them on a clean surface.

- Be careful not to interchange the roller rocker arms and the hydraulic lash adjusters.

Installing

Conditions:

• When installing the camshafts, the cam lobes for cylinder 1 - A - must point upward.






Procedure






- Rotate the crankshaft using the counterhold tool (T10172) in engine rotation direction to TDC for cylinder 1.

- Lightly coat the contact surfaces on bearing caps 7 and 8 with universal grease (G 052 735 A2) before installing.






- Install the hydraulic lash adjusters into the cylinder head and then mount the roller rocker arms on the valve stems and hydraulic lash adjusters.

- Make sure that all the roller rocker arms - 1 - properly contact the valve stem tips and are clipped into the respective hydraulic lash adjusters - 2 -.






- Oil the running surfaces of both camshafts.

- Place the camshaft carefully into the camshaft bearings on the cylinder head. Pay attention to the identification on the camshafts at the same time. Refer to => [ Camshaft Identification ] Application and ID.

- Pay attention to the installed position of the bearing caps.

Installed Position of the Camshaft Bearing Caps





The points - arrow A - on the intake and exhaust camshaft bearing caps face outward.

Intake Camshaft (- A -)






- Install and tighten the nuts for bearing caps 5 and 9 alternately and in a diagonal sequence to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 1 and 13 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing cap 7 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 3 and 11 to 5 Nm + an additional 45° (1/8) turn.

Exhaust Camshaft (- A -)






- Install and tighten the nuts for bearing caps 6 and 10 alternately and in a diagonal sequence to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 2 and 14 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing cap 8 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 4 and 12 to 5 Nm + an additional 45° (1/8) turn.

Continuation for Both Camshafts

- Install the camshaft bar (T10068 A) into both camshaft grooves.






- Check the control housing strainer for dirt before installing it. Refer to => [ Checking the Control Housing Strainer for Contaminants ] Control Housing Overview.

- Before installing the control housing, lubricate the seals on the camshafts.

- Oil the contact surfaces of the seals in the control housing and then slide the control housing slowly over the seals on the camshafts.

- Install the control housing and the bolts - arrows - using liquid locking fluid (D 000 600 A2). Tightening specification: 8 Nm + an additional 90° (1/4) turn.






- Install the camshaft adjusters. Refer to => [ Camshaft Adjuster ] Camshaft Adjuster.

- Clean the sealing surfaces of the cover.

- Replace the seals in the cover if they are damaged. Refer to => [ Cover Seal ] Cover Seal.

- Apply a thin bead of silicone adhesive sealant (D 176 501 A1) on the clean sealing surface of the cover.

- Install the cover and tighten all the bolts - arrows - hand tight.






- Then tighten all the bolts to specification, refer to => [ Cylinder Head and Cover Overview ] Cylinder Head and Cover Overview.

- Install the vacuum pump. Refer to => [ Vacuum Pump ] Vacuum Pump.

- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

Further installation is in the reverse order of removal.