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T4 AJT 2.5tdi 2003 project van Camshaft removal

T4
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1.6K views 3 replies 3 participants last post by  D0UF  
#1 ·
Hi guys I'm new to the forum, ive just bought a T4 with a coolant pump issue (leaking) found out the bearing had completely disintegrated but luckily no other damage apart from the belt chewing a hole in the plastic cover. anyway I'm half way through replacing the belts I noticed the cam seals leaking and figured I may as well change these while I have it stripped..... does anyone know if there is a procedure for removing/replacing the camshaft in a certain order? also if anyone has the OEM part numbers for the camshaft seals and the crankshaft front oil seal that would be great!

thanks
 
#2 ·
Hi guys I'm new to the forum, ive just bought a T4 with a coolant pump issue (leaking) found out the bearing had completely disintegrated but luckily no other damage apart from the belt chewing a hole in the plastic cover. anyway I'm half way through replacing the belts I noticed the cam seals leaking and figured I may as well change these while I have it stripped..... does anyone know if there is a procedure for removing/replacing the camshaft in a certain order? also if anyone has the OEM part numbers for the camshaft seals and the crankshaft front oil seal that would be great!

thanks
I'm not a qualified mechanic and I've absolutely no experience with the 5 cylinder engines, I've only worked on 4 cylinder engines, but according to the workshop manual it's possible to renew the seals on a 5 cylinder without removing the camshaft.
The cam needs to be in TDC position, according to the manual you just need to slacken the bearing cap bolts at whichever end you're working, prise out the old seal and insert the new seal
The complete removal of the camshaft has a sequence, I'm a bit puzzled as a 4 cylinder has 5 bearing caps and the workshop manual only mentions 4 bearing caps on a 5 cylinder, but the prcedure apparently is in TDC position to slacken bearing caps 2 and 4 first, half turns and diagonally, then slacken caps 1 and 3, half turns and diagonally.
Saying that I think it's advisable to research further or hopefully someone with more experience will join the thread as I just read the instructions from a book.

This site might help you find the OEM part nrs.

 
#3 ·
Removing the camshaft can cause leaks later when you refit it if you don't reseal the two end caps. It's probably more trouble than it's worth - as Dossbag says you can lever the old ones out and install new ones without camshaft removal.

The later engines (yours) use PTFE seals - these need incredible care to install as if you nick the seal edge even a tiny bit it will immediately leak. Older engines use simple sprung rubber seals that are much more forgiving. They are interchangeable.

My advice would be to use the older rubber style. They will last a long time even though it's 'old' technology.

Part number for the rubber seal is 068 103 085E - this is designed to run in both directions so can be used for both sides.
 
#4 ·
Perfect, thanks for your help! ill do it in place like you suggest then, I was going to check the cam bearings while I was there but the lobes look in really good condition and I have no reason to believe there would be any excessive wear anyway. its only done 90k