Camshaft: Service and Repair

Camshafts

Special tools, testers and auxiliary items required

• Thrust Piece (T10174)

• Assembly Tool (T10352)

• Counter Hold Tool (T10355)

• Locking Pin (T40011)

• Ignition Coil Puller (T40039)

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

• Sealant (D 154 103 A1)

• The sealing surfaces of the cylinder head cover and the upper cylinder head must not be reworked.

• The camshaft bearings are integrated in the cylinder head or cylinder head cover. The tension must be released from the camshaft timing chain before removing the cylinder head cover.

• If the cylinder head cover was removed, the sealing cap must be replaced.

• During installation, cable ties must be installed in the same location.

Removing

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

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

- Remove the noise insulation.

- Remove the front part of the right wheel housing liner and/or the right front wheel housing liner.

- Remove the bolts - arrows -.






- Lift the clamps - 1 and 2 - and remove the charge air pipe.

- Disconnect the connector from the camshaft adjustment valve 1 - 1 -.






- Remove the bolts - arrows - and then the camshaft adjustment valve 1.

- Remove the upper timing chain cover. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.


The control valve has left hand threads.

- Remove the control valve in the - direction of the arrow - using the assembly tool (T10352).






- Remove the bolts - arrows - and remove the bearing bracket.






- Rotate the vibration damper into the Top Dead Center (TDC) position - arrow - using the counter hold tool (T10355).






• The notch on the vibration damper must line up with the arrow mark - arrow - on the lower timing chain cover.

- Mark the drive chain/sprockets - arrows - with a waterproof marker. These marks are necessary for reinstallation.






- Remove the plug - arrow -.






- Lift the chain tensioner locking wedge by inserting a scribe or a suitable screwdriver into the hole in the chain tensioner in the - direction of arrow 1 -.






- Turn the crankshaft opposite the engine rotation direction in the - arrow 2 direction - and secure it using the locking pin (T40011).

• The intake camshaft switches in the engine rotation direction.

- Remove the guide pin - 1 - and guide the tensioning rail - 2 - downward.






- Remove the upper guide rail - 3 - by unlocking the latch located in the center with a screwdriver and pushing the guide rail forward.

• When the lower timing chain cover is installed, the loose chain on the crankshaft can not jump off.

- Remove the camshaft timing chain from the sprockets.


Danger of damaging the valves, piston head and lower timing chain cover.

• If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turned further.

• On this engine, when the valves are mounted, there is the danger that there are panels attached to the lower timing chain cover, which could fall and interfere with the chain; also a loose chain turned by the crankshaft can bend the panels. The panels can bend if the crankshaft is rotated when the chain is loose.

- Disconnect the connectors from the ignition coils and free up the wiring harness.

- Remove the ignition coils using the ignition coil puller (T40039).






- Disconnect the hose for the crankcase ventilation - 1 -.






- Remove the bolts - arrows -.

- Remove the charge air pipe bolt - arrow -.






- Loosen the hose clamp - 2 - and remove the charge air pipe together with the crankcase ventilation.






- Disconnect the vacuum line - 1 - and free up the wire.

- Disconnect the connector - 2 - from the camshaft position sensor (G40).

- Remove the cylinder head cover bolts in sequence - 1 through 6 -.






- Remove the cylinder head cover.

- Remove the camshafts.

- Prevent dirt and adhesive residue from entering the cylinder head.

Installing

• Tightening specifications, refer to => [ Valvetrain Overview ] Service and Repair.

• The sealing surfaces must be completely free of oil and grease.

• The pistons must not be positioned at TDC.

• Make sure that all roller rocker arms make contact correctly on the valve stem ends.

• Note the expiration date of the silicone sealant.

• The cover must be installed within 5 minutes after application of the silicone sealant.

- Remove any sealant residue on the cylinder head using a flat blade scraper.


Wear safety glasses.

• Prevent dirt and adhesive residue from entering the cylinder head.

- Remove any seal from the groove in the cylinder head cover as well as from any sealing surface using, for example, a rotating plastic brush.






- Clean sealing surfaces, must be free of oil and grease.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 2 mm).






- Lubricate the running surfaces of both camshafts.

- Place the camshaft into the cylinder head; the recesses - arrows - must be perpendicular to each other.






- Replace the cylinder head cover bolts.

- Apply the silicone sealant (D 154 103 A1) on the clean sealing surface of the cylinder head cover as shown - arrows -.






• Thickness of sealant bead: 2 to 3 mm.

• The cylinder head cover must be installed within 5 minutes after application of the silicone sealant.

• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake pipe.

• Note the expiration date of the sealant.

- Tighten the bolts in several passes in the tightening sequence, refer to => [ Cylinder Head Cover Bolt Tightening Sequence ] Service and Repair.

• Make sure the cylinder head cover is not tilted.

• Install the cap - 1 - without sealant using the thrust piece (T10174).






• Dimension - a -: 1 - 2 mm


When rotating the crankshaft, make sure the timing chain cannot damage any other components.

- Rotate the vibration damper into the TDC position - arrow - using the counter hold tool (T10355).






• The notch on the vibration damper must line up with the arrow mark - arrow - on the lower timing chain cover.

• The marked links of the timing chain must be positioned on the marks on the sprockets.

- Install the camshaft timing chain: The marks on the timing chain and sprockets - arrows - must align.






- Turn the intake camshaft using a wrench in the - direction of the arrow - and install the timing chain.

The rest of the installation is basically a reverse of the removal sequence.