Camshaft: Service and Repair

Camshaft, removing and installing





Special tools and equipment
^ 3415 Counter support
^ VAG1331 Torque wrench 5 to 50 Nm (3 7 to 37 ft. lbs.), or equivalent
^ VAG1332 Torque wrench 40 to 200 Nm (30 to 148 ft. lbs.), or equivalent
^ AMV 174 004 01 sealant

Removing
- Remove intake manifold upper part

Note: Seal the open portions of the lower intake manifold against dirt etc. with clean shop rags.

- Remove camshaft drive belt guard upper section.





- Set camshaft sprocket to cyl. 1 TDC by turning crankshaft.
^ Mark on camshaft sprocket must align with arrow on cylinder head cover.
- Release tensioning roller and take toothed belt off camshaft sprocket.
- Turn crankshaft back slightly.





- Remove camshaft sprocket using 3415 counter-hold. (Remove bolts from holes -arrows- before using tool.)
- Remove woodruff key from camshaft.
- Remove cylinder head cover.
- First remove bearing caps 5, 1 and 3, then loosen bearing caps 2 and 4 alternately and diagonally.

Installing
Conditions
^ Pistons must not be positioned at TDC.

Note:
^ When installing the camshaft No. 1 cylinder cams must point upward.





^ When installing the bearing cap note the offset. Before installing the camshaft install bearing caps and determine installation position.

Work sequence
- Oil camshaft contact surfaces.
- Install camshaft.
- Tighten bearing caps 2 and 4 alternately and diagonally.
^ Tightening torque: 20 Nm (15 ft. lbs.)
- Lightly coat bearing cap 1 contact surfaces with sealant AMV 174 004 01.
- Install bearing caps 3, 1 and 5 and tighten.
^ Tightening torque: 20 Nm (15 ft. lbs.)
- Insert woodruff key in camshaft.





- Install camshaft sprocket and tighten by counter-holding sprocket using 3415 counter-hold. (Remove bolts from holes -arrows- before using tool. )
^ Tightening torque: 100 Nm (74 ft. lbs.)

Note:
^ When the camshaft is turned, the crankshaft must not be at TDC. If so, there is a danger of damage to the valves or piston crowns.
^ The rest of the assembly is basically a reverse of the disassembly sequence.

Installing toothed belt and adjusting timing.

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