Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft

Special tools and workshop equipment required

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Sealant -AMV 174 004 01-

Removing –  Remove toothed belt → Chapter.

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

–  Loosen hub securing bolt -1-. –  To do this, use counterhold -T10051-. –  Loosen hub securing bolt by approx. 2 turns.

–  Fit puller -T10052- and align it with holes in hub. –  Apply tension to hub by evenly tightening puller until hub separates from taper of camshaft.   Note When doing this, hold puller with AF 30 mm spanner. –  Remove hub from taper of camshaft. –  Remove cylinder head cover. –  Remove rocker arm shafts.   Note First loosen both outer and then inner securing bolts respectively.

–  Mark rocker arm shafts using a permanent felt tip marker to prevent interchanging. This will prevent having to perform basic settings of unit injectors -arrows-. –  Remove tandem pump → Chapter.

–  First remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally. –  Remove camshaft. 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 4 alternately and diagonally to 8 Nm + turn 90° further (renew). –  Install bearing caps 5, 1 and 3 and also tighten to 8 Nm + turn 90° further (renew).   Note t  Seal separating surfaces of bearing caps 1 and 5 with AMV 174 004 01 → Fig.. t  Bearing cap 5 must be flush with outer edge of cylinder head, otherwise leaks can occur at the tandem pump. –  Install camshaft oil seal → Chapter.

–  Install injector rocker arm shafts with new securing bolts and tighten, first the inner -2- and then the outer -1-, evenly and in diagonal sequence. Specified torque: 20 Nm + turn 90° further. –  Place hub on camshaft.

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

–  Push camshaft belt pulley onto hub.   Note The toothed segment -arrow- of the camshaft belt pulley must be on top. –  Align camshaft belt pulley to centre position in elongated holes. –  Tighten securing bolts -1- to camshaft belt pulley by hand so 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 compensation elements must settle (otherwise valves will strike pistons).