Camshaft: Service and Repair

Camshafts

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Camshaft Bar (T10068 A)

• Counterhold Tool (T10172) (for engine code CNNA)

• Adjustment Tool (T10363)

• Counter-Holder Tool (T10069) (for engine code BLV)

• Silicone Adhesive Sealant (D 176 501 A1)

Removing

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

- Remove the air filter housing. Refer to => [ Air Filter Housing Overview ] Service and Repair.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

• Before disconnecting the connectors, mark them to the components.

- Disconnect the following connectors.






1 - Camshaft position sensor

2 - Camshaft adjustment valve 1

3 - Camshaft position sensor 2

4 - Exhaust camshaft adjustment valve 1

- Free up the wiring harness.

- Remove the vacuum pump. refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.

- Remove the upper and lower coolant pipes from the cover.

- Remove the cover bolts - arrows - and cover.






Carefully cover the lower chain compartment so no parts can fall in.

- Rotate the crankshaft in engine rotation direction to the Top Dead Center (TDC) for cylinder 1 mark.






Use the counterhold tool (T10172) for engine code CNNA or use counter-holder tool (T10069) for engine code BLV.

- It must be possible to install the camshaft bar (T10068 A) into both camshaft grooves.






- Also, secure the position of the high pressure pump chain sprocket using the adjustment tool (T10363). The mark - A - on the high pressure pump drive sprocket must be at the top.






• If vacuum pump drive pins are not vertical: Remove the camshaft bar (T10068 A). Rotate the crankshaft in engine rotation direction until the pins are vertical and then reinstall the camshaft bar (T10068 A).

- Remove chain tensioner - arrow -.






• Counter hold the camshaft using a 27 mm open end wrench on the recess - arrow -. The camshaft bar (T10068 A) must not be installed when loosening the camshaft adjuster bolts.






- Loosen and remove the camshaft adjuster bolts - 1 and 2 -.






- Remove both camshaft adjusters.

- Remove the 4 control housing bolts - 1 - and the housing - 2 - from the cylinder head and pull it off the camshafts in the - direction of the arrow -.






- Lay the timing chain to the side.

A - Intake Camshaft






- First, remove bearing caps 1 and 13.

- Remove bearing caps 3 and 11.

- Remove bearing cap 7.

- Loosen and remove bearing caps 5 and 9 alternately and in a diagonal sequence.

B - Exhaust Camshaft






- First, remove bearing caps 2 and 14.

- Remove bearing caps 4 and 12.

- Remove bearing cap 8.

- Loosen bearing caps 6 and 10, alternately and in a diagonal sequence.

Continuation for Both Camshafts

- Carefully remove the camshafts and place them on a clean surface.

- Remove the roller rocker arms together with the hydraulic lash adjusters and place them on a clean surface.

- Ensure that the roller rocker arms and the hydraulic lash adjusters are not interchanged.

Installing






Conditions:

• When installing the camshafts, the camshaft lobes for cylinder 1 - A - must point upward.

Procedure

- Coat the contact surface of bearing caps 7 and 8 lightly with molypaste lubricating paste (G 052 723 A2) or universal grease (G 052 735 A2) before installing.






- Insert the hydraulic lash adjusters in the cylinder head and install the roller rocker arms onto their respective valve stem end and adjuster.

- Make sure that all the roller rocker arms - 1 - properly contact the valve stem tips and are clipped into the respective hydraulic lash adjusters - 2 -.






- Oil the running surfaces of both camshafts.

- Place the respective camshaft carefully in the camshaft bearings in the cylinder head. While doing so, observe the identification of the camshafts. Refer to => [ Camshaft Identification ] Application and ID.

- Observe the installed position of the bearing caps.

Installed Position of the Camshaft Bearing Caps





The point - arrow A - on the intake and exhaust camshaft bearing caps face outward.

A - Intake Camshaft






- Install and tighten the nuts for bearing caps 5 and 9 alternately and in a diagonal sequence to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 1 and 13 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing cap 7 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts fro bearing caps 3 and 11 to 5 Nm + an additional 45° (1/8) turn.

B - Exhaust Camshaft






- Install and tighten the nuts for bearing caps 6 and 10 alternately and in a diagonal sequence to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 2 and 14 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing cap 8 to 5 Nm + an additional 45° (1/8) turn.

- Install and tighten the nuts for bearing caps 4 and 12 to 5 Nm + an additional 45° (1/8) turn.

Continuation for Both Camshafts






- Install the camshaft bar (T10068 A) into both camshaft grooves.

- Before installing the control housing, check the strainer for contamination. Refer to => [ Checking the Strainer for Contaminants ] Control Housing Overview.

- Before installing the control housing, check the seals for camshafts.

- Lubricate the contact surface on the seals inside the control housing. Slowly slide the control housing over the camshaft seals.

- Install liquid locking fluid (D 000 600 A2) on the control housing bolts - arrows - and tighten the bolts to specification. Tightening specification: 8 Nm.






- Install the camshaft adjuster with timing chain. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.

- Clean the sealing surfaces on the cover and on the cylinder head.

- If replacing the seals in the cover, refer to => [ Cover Seal, Installing ] Service and Repair.

- Coat the sealing surface on the cover with silicone adhesive sealant (D 176 501 A1) and install immediately.

• The silicone adhesive sealant (D 176 501 A1) hardens quickly.

- Install all the bolts - arrows - and tighten them just a little.






- Then, tighten the bolts to 8 Nm.

- Install the chain tensioner for the camshaft timing chain and tighten it to 50 Nm.

- Install the vacuum pump. Refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.

- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.