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 → Chapter. –  Remove fuel filter → Fuel supply - diesel engines; Rep. gr.20. –  If installed, remove supplementary fuel pump -V393- or fuel pump 2 -V277- → Fuel supply system - diesel engines; Rep. gr.20. –  Removed toothed belt from camshaft and high-pressure pump → Chapter. –  Remove cylinder head cover → Chapter.

–  Unscrew securing bolts -1- of camshaft pulley. –  Remove camshaft sprocket from hub.

–  Counterhold hub with counterhold tool -T10051- and release hub securing bolt -1-. –  Unscrew hub securing bolt approx. 2 turns.

–  Position puller -T10052- and align with hub holes. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.   Note Hold puller with 30 mm spanner. –  Remove hub from taper of camshaft. –  Remove vacuum pump → Chapter.

–  Unscrew securing bolts of retaining frame in sequence -24…1-. –  Remove retaining frame. –  Carefully remove 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. –  Sealing surfaces must be free of oil and grease. –  Oil running surfaces of camshafts. If not already done, set up camshaft fitting tool -T40094- as follows:

–  Remove supports -T40094/3-, -T40094/4- and -T40094/5- from base plate. Threaded connection is accessible from below.   Note If the supports of the camshaft fitting tool -T40094- are not yet marked, 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 positions. –  Place support -T40094/2- at position „A“ and support -T40094/1- at position „F“. –  First insert inlet camshaft as shown. Ensure that indentation -arrow- for cylinder head bolt faces »outwards«.

–  Position 0.50 mm feeler gauge and push the support -T40094/8- into inlet camshaft groove.

–  Insert exhaust camshaft and lock via groove -arrow- with -cover T40094/11-. –  Position clamping tool -T40096/1- on exhaust camshaft sprockets.   Caution Ensure that the clamping jaw marked with an arrow is seated on the wider gear.

–  Tighten clamping tool -T40096/1- using knurled wheel so that faces of gear teeth are in alignment. Use a 13 AF open-ended spanner. –  Slide exhaust camshaft towards inlet camshaft until teeth engage. –  Place retaining frame on camshafts. l  All camshaft bearings must be seated on the camshafts.

–  Position camshaft fitting tool -T40095- as shown, thereby fixing 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 holes-arrow- for retaining frame, make sure that these are not sealed due to surplus sealant.

Sealant bead for retaining frame –  Remove camshafts from camshaft fitting tool -T40095- together with retaining frame and camshaft fitting tool -T40094-. –  Carefully insert camshafts and retaining frame into cylinder head.

–  First tighten securing bolts of retaining frame finger-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 sequence -1…24-. Specified torque: 10 Nm –  Remove camshaft fitting tool -T40095- and clamping tool -T40096/1-. –  Renew camshaft 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 on camshaft.

–  Tighten hub securing bolt -1- to 100 Nm. Use counterhold tool -T10051- to do this.

–  Push camshaft sprocket onto hub.   Note The toothed segment -arrow- of the camshaft belt pulley must be on top. –  Insert securing bolts -1- by hand without play to camshaft sprocket. –  Lock hub with diesel injection pump locking pin -3359-. –  Install toothed belt and adjust the valve timing → Chapter. –  Install vacuum pump → Chapter. –  Install cylinder head cover → Chapter. –  Install fuel filter → Fuel supply - diesel engines; Rep. gr.20. –  If installed previously, install supplementary fuel pump -V393- or fuel pump 2 -V277- → Fuel supply system - diesel engines; Rep. gr.20.