SEAT Workshop Service and Repair Manuals

Removing and installing camshafts t  Removing → Anchor t  Fitting → Anchor

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Diesel injection pump locking pin -3359- (2 pcs), see equivalent → Anchor

t	Hose clamp -T10051-, see equivalent → Anchor

t	Extractor -T10052A-, see equivalent → Anchor

t	Camshaft assembly tool -T40094A-,see equivalent → Anchor

t	Camshaft insert tool -T40095-, see equivalent → Anchor

t	counterhold -T40096-, see equivalent → Anchor

t  Torque wrench -VAG 1331-, see equivalent → Anchor.

t  Torque wrench -VAG 1332-, see equivalent → Anchor. t  Silicone sealant → Spare parts catalogue

Removing –  Loosen the engine cover at the locations -arrows- and remove. –  Remove the injectors → Chapter –  Install fuel rail → Chapter. –  Detach notched belt from camshaft and high pressure pump → Chapter. –  Remove cylinder head cover → Chapter

–  Extract the camshaft sprocket bolts -1-. –  Detach camshaft sprocket from hub.

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

–  Fit the Extractor tool -T10052A- and align it with the hub holes. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening the Extractor tool-2- until hub separates from taper of camshaft.   Note During this step, hold the extractor tool with a 30 mm wrench. –  Remove hub from taper of camshaft. –  Remove exhauster pump → Chapter.

–  Unscrew the securing bolts of the bearing cap module in the sequence -24 ... 1-. –  Remove the bearing cap module. –  Take out camshafts carefully. Installing   Note t  When installing the camshafts, the cams of cylinder 1 should be pointing upwards. t  Do not interchange used bearing shells (mark). t  When fitting the camshaft, ensure that the securing lugs of the half bearing in the bearing cap module and cylinder head are correctly seated. t  Seal the contact surface between the bearing cover module and the cylinder head using silicone → Spare parts catalogue.   Caution The camshafts may be attached as described below and only with the Camshaft fitting tool -T40094A-. Otherwise the axial bearings of the bearing cap module could be damaged, as a result of which the cylinder head would have to be replaced.

–  Remove the remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar.   Caution Make sure that no sealant residue gets into the cylinder head or the bearings. –  Clean sealing surfaces. These must be free of oil and grease. –  Oil the camshaft running surfaces. Prepare the Camshaft fitting tool -T40094A- as follows:

–  Remove the mounts -T40094/3-, -T40094/4- and -T40094/5- from the base plate. Threaded connection is accessible from below.   Note When the mount of the camshaft assembly device -T40094A- does not have any markings, mark the mount removed with figures to enable them to be mounted back together correctly.

–  Instead of the integrated brackets, attach the bracket -T40094/9- and the bracket -T40094/10- to the exterior freed holes. –  Fit the support -T40094/2- at position „A“ and the support -T40094/1- at position „F“.

–  First attach the inlet camshaft as shown. Ensure that the projection -Arrow- for the cylinder head bolt shows »Outwards«. –  Attach a 0.50 mm gauge and push the bracket -T40094/8- in the groove of the inlet camshaft.

–  Now attach the exhaust camshaft and lock above its groove -Arrow- with the Cover -T40094/11-. –  Attach the camshaft assembly tool -T40096/1- to the toothed wheels of the exhaust camshaft.   Caution Make sure that the clamping piece marked with an arrow is positioned on the gear with the larger width.

–  Secure the camshaft assembly tool -T40096/1- with the knurled wheel till the tooth flanks are aligned. If required, counterhold with an open-ended wrench SW 13. –  Push the exhaust camshaft to the inlet camshaft till the teeth interlock. –  Fit the bearing cap module on the camshaft. l  All the camshaft bearings must be supported on the camshaft.

–  Fit the Camshaft insert tool -T40095- as shown and thus, secure the camshafts with the bearing cap module. –  Detach cover -T40094/11- . –  Pull support -T40094/8- out of inlet camshaft groove.

–  Cut off tube nozzle at upper marking (nozzle Ø: approx. 2 mm). –  Apply 2-3 mm wide sealant beads on the clean sealing surfaces of the cylinder head, as shown in the ill.   Note

The sealant beads may not be thicker, since excess sealant can otherwise get into the camshaft bearing. –  Remove camshafts from the camshaft insert tool -T40094A- together with bearing cover module and camshaft insert tool -T40095-. –  Set the camshafts and the bearing cap module carefully on the cylinder head.

–  Unscrew the securing bolts of the bearing cap module in the sequence -1 ... 24- tighten manually. l  The retaining frame must be supported on the entire surface on the cylinder head. –  Unscrew the securing bolts of the bearing cap module in the sequence -1 ... 24- tighten to the final torque. Tightening torque: 10 Nm –  Detach clamping tool -T40095- and clamping tool -T40096/1- . –  Renew camshaft seal → Chapter. –  Using a suitable drift, knock in new sealing cap (core plug) → Item on the cylinder head until flush. The remaining installation steps are carried out in reverse sequence - note the following points:   Note t  After installing cam shaft, the engine must not be started for approx. 30 minutes. Hydraulic compensation elements must be set. (Else the valves fit on the pistons). t  After working on valve gear, carefully crank engine at least 2 revolutions by hand to ensure that no valves make contact on starting. –  Position hub on camshaft.

–  Tighten hub securing bolt -1- to 100 Nm. Use counter-hold tool -T10051- for this purpose.

–  Push camshaft sprocket onto hub.   Note The cogged part -arrow- of the camshaft cogwheel should face upwards. –  Align camshaft sprocket centrally in elongated holes. –  Hand-tighten securing bolts -1- on camshaft sprocket so that there is no play. –  Immobilise the hub using the retention tool -3359-. –  Install notched belt (adjust valve timing) → Chapter. –  Install exhauster pump → Chapter. –  Install cylinder head cover → Chapter.