Removal and Replacement

Camshafts, removing and installing
(with cylinder head installed)

Removing

Installing





Special tools, testers and auxiliary items required
^ Retainer 3036
^ Bracket for chain adjustment 3366
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Sealing compound D 454 300 A2

Removing
- Remove engine cover.
- Remove toothed belt guard upper part.





- Set camshaft pulley to TDC No. 1 cylinder by turning crankshaft. Mark on camshaft pulley must align with cylinder head marking.
- Remove cylinder head cover.
- Remove toothed belt only from camshaft sprocket.
- Turn crankshaft back slightly.
- Remove camshaft sprocket. When loosening bolt hold camshaft pulley with retainer 3036.
- Remove woodruff key from camshaft.
- Remove camshaft position sensor housing.
- Remove washer and hood for camshaft position sensor.





- Clean drive chain and chain sprockets of camshafts, in front of both arrows on bearing caps, and mark installation position with a colored mark.

Note:
^ Do not mark chain with a punched mark, notch or similar!
^ The distance between both arrows or the colored marks is 16 rollers of the drive chain.





- Secure chain tensioner or camshaft adjuster with bracket for chain adjustment 3366.

Note:
^ Excessive tensioning of the chain tensioner bracket may damage the chain tensioner or the camshaft adjuster.





- Remove bearing cap 3 and 5 of intake and exhaust camshafts first.
- Remove double bearing cap.
- Remove both bearing caps on chain sprockets of intake and exhaust camshafts.
- Remove securing bolts of chain tensioner or camshaft adjuster.
- Loosen bearing cap 2 and 4 of intake and exhaust camshafts in a cross-over sequence and remove.
- Remove intake and exhaust camshaft, chain tensioner or camshaft adjuster and bracket for chain adjustment 3366.

Installing





Note:
^ When camshafts are installed, No. 1 Cyl. cams must point upward.
^ When installing the bearing cap, observe that the cap marking is legible from the intake side of the cylinder head.

- If reusing old drive chain, install drive chain corresponding to color marking on both camshafts.

Note:
^ When using a new drive chain, the distance between the notches - A - and - B - on the camshafts must be 16 rollers of the drive chain.
^ The figure shows where the 1st and the 16th roller of the chain sprocket must be positioned.
^ The notch - A - is offset slightly inward to the chain roller - 1 -.





- Replace metal gasket for chain tensioner or camshaft adjuster and apply a bit sealant D 454 300 A2 to shaded area.
- Press chain tensioner or camshaft adjuster between drive chain.
- Oil running surfaces of camshafts.
- Insert camshafts with drive chain and chain tensioner or camshaft adjuster into cylinder head.
- Tighten chain tensioner or camshaft adjuster to 10 Nm (observe dowel sleeves).





- Tighten bearing caps 2 and 4 of intake and exhaust camshafts using a cross-over sequence and tighten to 10 Nm (observe dowel sleeves).





- Install both bearing caps on chain sprockets of intake and exhaust camshafts. Check camshafts for correct seat - arrow - and tighten bearing caps to 10 Nm (observe dowel sleeves).
- Remove bracket for chain tensioner or camshaft adjuster 3366.





- Apply a thin coat of sealant D 454 300 A2 to shaded area of double bearing cap and tighten to 10 Nm (observe dowel sleeves).
- Install other bearing caps and tighten to 10 Nm (observe dowel sleeves).





- Install camshaft pulley (narrow web shows outward - arrows - and TDC marking is visible) and tighten securing bolt to 65 Nm (use retainer 3036).





- Check position of camshafts to each other.

Further assembly is basically the reverse of the disassembly procedure.
- Install toothed belt.

Note:
^ When the camshafts have been installed the engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).