Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft

Special tools and workshop equipment required

t	Counter-hold tool -T10051-

t	Puller -T10052-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Sealant -AMV 17400401-

Removing –  Remove poly V-belt → Chapter. –  Remove toothed belt → Chapter.

–  Remove securing bolts for camshaft toothed belt pulley -1-. –  Pull camshaft toothed belt pulley off hub.

–  Loosen hub securing bolt -1-. –  To do this, use counter-hold tool -T10051-. –  Loosen hub securing bolt about 2 turns.

–  Fit puller -T10052- and align it with holes in hub. –  Insert securing bolts -1- in hub. –  Apply tension to hub by evenly tightening puller central bolt -2- until hub releases from taper of camshaft.   Note When doing this, hold puller with 30 mm spanner. –  Remove hub from taper of camshaft. –  Remove cylinder head cover. –  Remove rocker arm shaft.   Note First loosen the outer and then both inner securing bolts, using diagonal sequence. –  Remove tandem pump → Chapter. –  First remove bearing caps 2 and 3. Loosen bearing caps 1 and 4 alternately and diagonally.   Note Bearing cap 4 is marked as bearing cap 5 Installing   Note t  When camshaft is installed, No. 1 cylinder cams must point upwards. t  Do not interchange used bearing shells (mark). t  When installing the camshaft, ensure proper seating of retaining lugs in bearing caps and cylinder head. t  Before installing bearing caps, ensure that cylinder head bolt washers are inserted in the cylinder head. –  Oil running surfaces of shell bearings. –  Tighten bearing caps 2 and 3 alternately and diagonally to 8 Nm + 1/4 turn (90°) further. –  Install bearing caps 1 and 4 and also tighten to 8 Nm + 1/4 turn (90°) (renew bolts).   Note t  Bearing cap 4 is marked as bearing cap 5 t  Seal parting surfaces of bearing caps 1 and 4 with sealant -AMV 17400401- → Fig.. t  Bearing cap 4 must be flush with outer edge of cylinder head, otherwise leaks can occur at the tandem pump. –  Install camshaft oil seal → Chapter. –  Install rocker arm shaft, first tighten the inner and then the outer securing bolts evenly using diagonal sequence. Torque setting: 20 Nm + 1/4 turn (90°) further. –  Set hub on camshaft.

–  Tighten hub securing bolt -1-Tightening torque: 100 Nm. –  To do this, use counter-hold tool -T10051-.

–  Push camshaft toothed belt pulley onto hub.   Note The toothed segment -arrow- of the camshaft belt pulley must be on top. –  Align camshaft toothed belt pulley at centre of elongated holes. –  Hand tighten securing bolts -1- to camshaft toothed belt pulley so that there is no play. –  Lock the hub using diesel injection pump locking pin -3359-. –  Install and tension toothed belt → Chapter. –  Install tandem pump → Chapter.   Note When new bucket tappets have been installed the engine must not be started for about 30 minutes. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons).