Camshaft, Lifters and Push Rods: Service and Repair

Camshaft, removing and installing
Special tools and material





^ 3036 Counter-holding tool
^ T40001 Two-arm puller
^ VAG 1331 Torque wrench (5 to 50 Nm) or equivalent
^ VAG 1921 Spring clamp pliers
^ AMV 174 004 01 Sealer

Removing





- Disconnect fuel pressure and return lines on fuel filter (arrows).
- Cap lines to prevent dirt from entering lines.
- Remove right headlight. Refer to Lighting and Horns.
- Remove connecting line between charge air cooler and intake manifold.
- Remove toothed belt upper guard cover.
- Remove vacuum pump for brake booster.
- Remove valve cover.
- Remove toothed belt from camshaft sprocket.
- Slightly turn crankshaft counterclockwise of engine rotation.





- Loosen center bolt on camshaft sprocket by 1 turn, counter holding with tool 3036.

Note: Do not use alignment tool 34 18 as a counter-hold tool. Always use tool 3036.





- Install two-claw puller T40001 with claw -A- and claw -13- to center of camshaft sprocket and pull sprocket off. Counterhold puller with wrench -C-.
- Remove camshaft sprocket.
- Remove bearing caps 5, 1, and 3.
- Loosen bearing caps 2 and 4 in steps and diagonally.

Installing
Requirements
^ Pistons must not be at TDC.

Note:
^ When installing the camshaft, the cam lobes for cylinder 1 must point upward.
^ When installing be sure to note offset of bearings.





- Lubricate bearing camshaft surfaces with oil.
- Install camshaft.
- Tighten bearing caps 2 and 4 alternately and diagonally to 20 Nm (15 ft. lbs.).
- Lightly coat contact face of bearing cap with sealer AMV 17400401.
- Install bearing shells 3, 1 and 5 and also tighten to 20 Nm (15 ft. lbs.).
- Lightly tap bearing cap 5 to fit camshaft.
- Install camshaft sprocket together with toothed belt and position with bolt (camshaft must still turn).
The installation is in reverse order of removal.
Toothed belt, installing
- Install connecting line between charge air cooler and intake manifold
- Install fuel pressure and return lines to fuel filter.
- Install right headlight. Refer to Lighting and Horns.
- Adjust headlights if necessary. Refer to Lighting and Horns.

Note: Do NOT start the engine for approximately 30 minutes after new lifters have been installed. The hydraulic compensation elements must settle or the valves will strike pistons.