Volkswagen Workshop Service and Repair Manuals

Removing and installing camshafts Special tools and workshop equipment required

t  Two-arm puller -T40001-

t  Counterhold tool -3036- t  Sealant -D 154 103 A1- Removing camshafts   Note t  The sealing surfaces on bottom of retaining frame and top of cylinder head must not be reworked. t  The camshaft bearings are integrated into the cylinder head and the retaining frame. The toothed belt must be relieved of tension before the retaining frame is removed. t  Renew camshaft oil seal and sealing cap if retaining frame has been unfastened. –  Remove camshaft adjuster → Chapter. –  Remove toothed belt:    Vehicles with split toothed belt guard → Chapter.    Vehicles without split toothed belt guard → Chapter.

–  Loosen securing bolt for camshaft pulley and unscrew approx. 10 mm (use counterhold -3036-).

–  Pull camshaft sprocket off with two arm puller -T40001-, claw -T40001/6- and claw -T40001/7-. Two arm puller -T40001- is supported on securing bolt -arrow-. –  Remove securing bolt and camshaft pulley. –  Remove rear toothed belt guard from cylinder head. –  Loosen retaining frame bolts evenly working from outside inwards and remove retaining frame. –  Carefully lift out the camshafts and place them down on a clean surface.

–  Remove old sealant from groove in retaining frame as well as from sealing surfaces. –  Prevent dirt and residual sealant from entering cylinder head. Installing camshafts   Note t  Sealing surfaces must be free of oil and grease. t  The pistons must not be positioned at TDC. t  Ensure that all roller rocker fingers are properly seated on valve stem ends. –  Oil running surfaces of camshafts.

–  Insert camshafts carefully in the camshaft bearings of cylinder head. Cams -A- of cylinder 4 must face each other.

–  Apply even, slightly projecting sealant bead (D 154 103 A1) into clean groove of retaining frame.   Note t  Sealant must not be applied too thickly. If necessary wipe away excess sealant with a lint-free cloth. t  The retaining frame must be positioned and bolted on without interruption because the sealant begins to harden immediately when the sealing surfaces come into contact with each other. t  Observe expiry date of sealing compound. –  Place retaining frame on cylinder head. –  Tighten bolts lightly in several stages, working from inside outwards.

–  Then tighten bolts in the sequence shown to 8 Nm + 1/4 (90°) turn further. –  Drive in sealing cap → Item about 1…2 mm using thrust piece -3334-. –  Install camshaft oil seal → Chapter. –  Install rear toothed belt guard. –  Insert parallel key into camshaft.

–  Install camshaft toothed belt pulley. To tighten bolt, hold camshaft toothed belt pulley in position using counterhold -3036-. Specified torques → Chapter   Note t  When turning the camshaft, the pistons must not be at TDC. This could otherwise result in damage to valves and pistons. t  Ensure the parallel key is correctly seated. –  Install toothed belt.    Vehicles with split toothed belt guard → Chapter.    Vehicles without split toothed belt guard → Chapter. –  Install camshaft adjuster → Chapter. –  Install cylinder head cover → Chapter. Further assembly is basically the reverse of the dismantling sequence.