Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft

Special tools and workshop equipment required

t	Diesel injection pump locking pin -3359-

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Camshaft fitting tool -T40094-

t	Camshaft clamping tool -T40095-

t	Camshaft fitting tool -T40096-

t  Torque wrench -V.A.G 1331/-

t  Torque wrench -V.A.G 1332/- t  Silicone adhesive sealant -D 176501 A1- Removing –  Remove engine cover panel → Chapter. –  Remove fuel filter → Fuel supply - Diesel engines; Rep. gr.20. –  Remove supplementary fuel pump -V393- or fuel pump 2 -V277- → Fuel supply - Diesel engines; Rep. gr.20. –  Take toothed belt off camshaft and high-pressure pump → Chapter. –  Remove cylinder head cover → Chapter.

–  Remove securing bolts for camshaft toothed belt pulley -1-. –  Detach camshaft pulley from hub.

–  Counterhold hub with counterhold -T10051- and loosen securing bolt -1- of hub. –  Loosen hub securing bolt about 2 turns.

–  Fit puller -T10052- and align it with holes in hub. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.   Note When doing this, hold puller with 30 mm spanner. –  Remove hub from taper of camshaft. –  Remove vacuum pump → Chapter.

–  Remove securing bolts of retaining frame in sequence -24 … 1-. –  Remove retaining frame. –  Carefully take out camshafts. Installing   Note Seal parting surface between retaining frame and cylinder head using silicone adhesive sealant -D 176 501 A1-.   Caution The camshafts may only be installed with the camshaft fitting tool -T40094- as described below. The axial bearings in the retaining frame will otherwise be damaged beyond repair and the cylinder head will have to be renewed. –  Remove sealant residues on cylinder head and retaining frame, e.g. using a rotating plastic brush.   Caution Make sure that no sealant residue gets into the cylinder head or the bearings. –  Clean sealing surfaces; they must be free of oil and grease. –  Oil the camshaft running surfaces. Set up camshaft fitting tool -T40094- as follows:

–  Remove supports -T40094/3-, -T40094/4- and -T40094/5- from base plate. Threaded connection from below.   Note If the supports of the camshaft fitting tool -T40094- are not marked at present, mark the removed supports, e.g. with number stamps, so they can be fitted in the original positions later.

–  Install supports -T40094/9- and -T40094/10- instead at vacant outer places. –  Place support -T40094/2- at position labelled „A“ and support -T40094/1- at position labelled „F“. –  First position inlet camshaft as illustrated. Ensure that indentation -arrow- for cylinder head bolt faces »outwards«.

–  Set 0.50 mm feeler gauge in place and push support -T40094/8- into groove on inlet camshaft.

–  Now set exhaust camshaft in place and lock by inserting -cover T40094/11- into groove -arrow-. –  Fit clamping tool -T40096/1- onto exhaust camshaft gears.   Caution Ensure that the clamping jaw marked with an arrow is seated on the wider gear.

–  Tighten clamping tool -T40096/1- using knurled thumb wheel so that faces of gear teeth are in alignment. If necessary, use 13 mm open-end spanner. –  Slide exhaust camshaft towards inlet camshaft until gear teeth engage. –  Fit retaining frame onto camshafts. l  All camshaft bearings must be seated on the camshafts.

–  Set clamping tool -T40095- in place as illustrated in order to hold camshafts in position in retaining frame. –  Remove cover -T40094/11-. –  Pull support -T40094/8- out of inlet camshaft groove.

–  Cut off nozzle on tube at front marking (Ø of nozzle approx. 2 mm). –  Apply beads of sealant (approx. 2…3 mm wide) -arrows- onto clean sealing surfaces of cylinder head as illustrated.   Caution Risk of soiling camshaft bearings due to surplus sealant and risk of sealing oil supply bores. t  Do not apply sealant beads thicker than specified. t  In area of oil supply bores -arrow- for retaining frame, make sure that these are not sealed due to surplus sealant.

Sealant bead for retaining frame –  Take camshafts out of camshaft fitting tool -T40095- together with retaining frame and clamping tool -T40094-. –  Carefully position camshafts and retaining frame in cylinder head.

–  First tighten securing bolts of retaining frame hand-tight in sequence -1 … 24-. l  The retaining frame should make contact with the cylinder head over the complete surface. –  Tighten retaining frame bolts to final torque in the sequence -1…24-. Specified torque: 10 Nm –  Remove clamping tool -T40095- and camshaft fitting tool -T40096/1-. –  Renew camshaft oil seal → Chapter. –  Using a suitable drift, knock new sealing cap (core plug) → Item in cylinder head until flush. Perform further installation in reverse order, paying attention to the following:   Caution Avoid damage to valves and piston crowns after working on valve gear. t  Because hydraulic compensation elements have to settle, engine must not be started for approx. 30 minutes after installing camshafts. t  Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. –  Fit hub onto camshaft.

–  Tighten hub securing bolt -1- to 100 Nm. To do this, use counterhold -T10051-. –

–  Push camshaft toothed belt pulley onto hub.   Note The toothed segment -arrow- of the camshaft belt pulley must be on top. –  Hand tighten securing bolts -1- to camshaft toothed belt pulley so that there is no play. –  Lock hub using locking pin -3359-. –  Install toothed belt and adjust valve timing → Chapter. –  Install vacuum pump → Chapter. –  Install cylinder head cover → Chapter. –  Remove fuel filter → Fuel supply - Diesel engines; Rep. gr.20. –  Remove supplementary fuel pump -V393- or fuel pump 2 -V277- → Fuel supply - Diesel engines; Rep. gr.20.