1.2 TDI CR engine (EA189) · Cylinder head, valve gear · Valve gear

Removing and installing camshafts

Special tools and workshop equipment required

  • Diesel injection pump locking pin - 3359-
  • Counter-hold tool - T10051-
  • Puller - T10052-
  • Camshaft fitting tool - T40094-
  • Camshaft clamping tool - T40095-
  • Camshaft fitting tool - T40096-
  • Torque wrench - V.A.G 1331/-
  • Torque wrench - V.A.G 1332/-
  • Sealant as per ⇒ ETKA (Electronic Parts Catalogue)

3.5.1 Removing

»Carry out the following work sequence«

  • Unscrew camshaft sprocket securing bolts -1-.
  • Remove camshaft sprocket from hub.
  • Counterhold hub with counterhold - T10051- and loosen hub securing bolt -1-.
  • Unscrew hub securing bolt approx. 2 turns.
  • Position puller - T10052- and align with hub holes.
  • Tighten securing bolts -1-.
  • Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.
  • Remove hub from camshaft taper.
  • Remove vacuum pump ⇒ Item 4 (page 67).
  • Unscrew retaining frame securing bolts in sequence -20…1-.
  • Remove retaining frame.
  • Carefully remove camshafts.

3.5.2 Installing

  • Remove sealant residue from cylinder block and retaining frame using, for example, a plastic rotary brush.
  • Clean sealing surfaces. They must be oil and grease free.
  • Oil running surfaces of camshafts.

Set up camshaft fitting tool - T40094- for camshafts as follows:

  • Remove supports -T40094/3-, -T40094/4- and -T40094/5- from base plate. Threaded connection is accessible from below.
  • Instead, position supports -T40094/9- and -T40094/12- on outer positions which have become free.
  • Place support -T40094/2- in position “A”. Place support - T40094/1- in position “D”.
  • First insert inlet camshaft as shown. Ensure that indentation -arrow- for cylinder head bolt faces »outwards«.
  • Fit 0.50 mm feeler gauge. Push support -T40094/8- into inlet camshaft groove.
  • Insert exhaust camshaft, lock via its groove -arrow- with -cover T40094/11-.
  • Position clamping tool - T40096/1- on exhaust camshaft sprockets.
  • Tighten clamping tool - T40096/1- using knurled wheel so that faces of gear teeth are in alignment. Use a 13 mm open-end spanner to assist if necessary.
  • Slide exhaust camshaft towards inlet camshaft until teeth engage.
  • Position retaining frame on camshafts.
  • All camshaft bearings must be seated on the camshafts.
  • Position camshaft fitting tool - T40095- as shown, thereby locking camshafts in retaining frame.
  • Remove cover - T40094/11-.
  • Pull support - T40094/8- out of inlet camshaft groove.
  • Cut off nozzle on tube at front marking (∅ of nozzle approx. 2 mm).
  • Apply sealant beads (approx. 2 … 3 mm wide) -arrows- as shown in illustration on clean sealing surfaces of cylinder head.
  • Install new cap ⇒ Item 17 (page 98) flush on cylinder head.
  • Take camshafts out of camshaft fitting tool - T40095- together with retaining frame and camshaft fitting tool - T40094-.
  • Carefully insert camshafts and retaining frame into cylinder head.
  • First, tighten securing bolts of retaining frame hand-tight in sequence -1…20-.
  • The retaining frame should make contact with the cylinder head over the complete surface.

Perform further installation in reverse order, paying attention to the following:

  • Place hub back onto camshaft.
  • Tighten hub securing bolt -1- to 100 Nm. Use counter-hold tool - T10051- to do this.
  • Push camshaft sprocket onto hub.
  • Hand tighten securing bolts -1- to camshaft sprocket so that there is no play.