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- Removing   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. –  Removing camshaft adjuster → Chapter. –  Remove toothed belt → Chapter.

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

–  Pull off camshaft pulley using puller -T40001-, hook -T40001/6- and hook -T40001/7-. The puller -T40001- is supported by the securing bolt -arrow-. –  Remove securing bolt and camshaft pulley. –  Remove rear toothed belt guard from cylinder head. –  Evenly loosen retaining frame bolts from outside to inside and remove retaining frame. –  Carefully lift out camshafts from above and place down on a clean surface.

–  Remove old sealant from retaining frame groove and from sealing surfaces. –  Dirt and sealant residues must not enter cylinder head. Installing   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 both camshafts.

–  Carefully place camshafts into camshaft bearings of cylinder head. Cams -A- of cylinder 4 must face each other.

–  Apply an even, slightly raised bead of sealant with sealant -D 154 103 A1- into clean retaining frame groove.   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 onto cylinder head. –  Tighten new bolts gently, from inside outwards.

–  Then tighten bolts in the sequence shown to 8 Nm + 1/4 (90°) turn further. –  Drive sealing cap → Item in approx. 1…2 mm deep using thrust piece -3334-. –  Install camshaft oil seal → Chapter. –  Install rear part of toothed belt guard. –  Insert Woodruff key in camshaft. –  Install camshaft pulley to tighten bolt, hold camshaft pulley with 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 → Chapter. –  Install camshaft adjuster → Chapter. –  Install cylinder head cover → Chapter. Further assembly is basically the reverse of the dismantling sequence.