Removing and installing camshaft housing

Special tools and workshop equipment required

• Torque wrench (5 … 50 Nm) - V.A.G 1331-
• Tapered roller bearing puller - T10094-
• Two studs (M6 x 70)

• D 154 103 A1 Sealant

1.5.1 Removing

• Remove air filter housing ⇒ 1.8 Removing and installing air filter housing.

• First check whether a coded radio is fitted. If so, obtain antitheft code.
• With ignition switched off, disconnect battery earth strap.
• Remove cover for camshaft housing, if fitted.
• First remove main drive toothed belt ⇒ 1.3 Removing, installing and tensioning toothed belt.

• Pull 4-pin connectors off ignition coils.
• Remove ignition coils. Use puller - T10094- for this purpose.
• Remove wiring guide from camshaft housing.

• Remove securing bolts -arrows- from connector bracket.

• Remove coolant breather line from camshaft housing.
• Disconnect connector from Hall sender.
• Remove securing bolt for toothed belt rear guard (near righthand lifting eye).
• Loosen camshaft housing bolts from outside to inside, alternately and diagonally and remove.
• Carefully lift camshaft housing off.

1.5.2 Installing

Conditions

• The pistons cannot be positioned at TDC.
• Camshaft pulleys locked into camshaft housing fitting holes with camshaft lock - T10016- and secured against turning.

• Remove sealant residue from cylinder head and camshaft housing with commercially available sealant remover.
• Also prevent dirt and residual sealant from entering cylinder head.
• Clean sealing surfaces carefully. They must be free of oil and grease.

• Apply a thin and uniform layer of sealant to clean sealing surface of camshaft housing.

• Ensure that all roller rocker fingers contact valve stem ends -1- correctly and that they are clipped into their respective support elements -2-.
• Screw two studs (M 6 x 70) into cylinder head before installing camshaft housing.

• Carefully fit camshaft housing vertically from above onto studs -arrows- and cylinder head dowel pins.

• Evenly tighten new camshaft housing securing bolts from inside to outside alternately and diagonally.

Ensure that camshaft housing is not canted. Specified torque 10 Nm + ¹/4 turn (90°) further.

Further assembly is basically a reverse of the dismantling sequence.

Specified torque for securing bolts of camshaft housing cover: 10 Nm