Camshaft: Service and Repair

Camshafts

Special tools, testers and auxiliary items required

• Thrust piece (T10174)

• Assembly tool (T10352)

• Counter holder tool (T10355)

• Locking pin (T40011)

• Ignition coil puller (T40039)

• Torque wrench 5-50 Nm (VAG 1331)

• Silicone sealant (D 154 103 A1)

• Cable tie

• Flat scraper

• Hand drill with plastic brush attachment

• Protective eyewear

Removing

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

• The camshaft bearings are integrated in the cylinder head and 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 loosened, then the cover must be replaced.

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

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

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid or vacuum) and electrical wires so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

- 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 right front wheel.

- Remove the right front (rear) wheel housing liner.

- Remove the charge air pipe bolts - arrows -.





- Remove the charge air pipe by lifting the clamps - 1 and 2 -.

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





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

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

CAUTION!
The control valve has left hand threads.

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





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





- Rotate the vibration damper to the "OT" position - arrow - using the (T10355):





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

- Carefully mark the drive chain and 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 - arrow direction 1 -.





- Rotate the crankshaft in the opposite direction of engine rotation - arrow direction 2 - and secure the chain tensioner with the (T40011).

• The intake camshaft switches in the engine direction of rotation.

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





- Remove the camshaft timing chain guide rail - 3 - by unlocking the latch 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.

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

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

• Panels are installed on the lower timing chain cover to prevent the chain from falling down. The panels can bend if the crankshaft is rotated when the chain is loose.

- Remove the ignition coils with output stages. Refer to --> [ Ignition Coils with Power Output Stages ] Service and Repair, and lay the wiring harness to the side.





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

- Remove the bolts - arrows -.

- Remove the air guide pipe bolt - arrow -.





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





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

- Disconnect the electrical connector from the Camshaft Position (CMP) sensor - 2 -.

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





- Remove the cylinder head cover.

- Remove the camshafts.

- Prevent dirt and adhesive residue from entering cylinder head.

Installing

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

• Use silicone sealant (D 154 103 A1).

• Sealing surfaces must be completely free of oil and grease.

• The pistons must not be positioned at Top Dead Center (TDC)

• Make sure that all roller cam followers make contact correctly on valve stem ends.

• Note the expiration date of the silicone sealant (D 154 103 A1).

• The cylinder head cover must be installed within 5 minutes after applying the silicone sealant (D 154 103 A1).

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

CAUTION!
Wear safety glasses.

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

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





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

- Cut the tube nozzle at the front marking (diameter of nozzle approximately 2 mm).





- Lubricate the running surfaces of both camshafts.

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





- Replace the cylinder head cover bolts.

- Apply the silicone sealant 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 applying the silicone sealant.

• The sealant bead must not be thicker than specified, otherwise excess sealant could get into oil pan and clog strainer in intake line of oil pump.

• Note the expiration date of the sealing compound.

- Tighten the bolts in several steps:

• Tightening sequence and specification, refer to --> [ Cylinder Head Cover Bolt Tightening Sequence and Specification ] Service and Repair.

• Make sure the cylinder head cover is not tilted.

- Install the cover - 1 - without sealant using the (T10174):





• Dimension - a - = 1 to 2 mm.

CAUTION!
When turning the crankshaft, make sure the timing chain cannot damage any other components.

- Rotate the vibration damper to the "OT" position - arrow - using the (T10355):





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

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

- Install the camshaft timing chain:





• The markings on the drive 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.