Camshaft: Service and Repair
Camshaft
Special tools, testers and auxiliary items required
• Assembly Tool (T10352)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Lever (T40243)
• Locking Tool (T40267)
• Camshaft Locator (T40271)
• Thrust Piece (T10174)
• Ignition Coil Puller (T40039)
• Silicone Sealant (D 154 103 A1)
• The sealing surfaces of the cylinder head cover and 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 removed, the sealing cap must be replaced.
• During installation, cable ties must be installed at the same location.
Removing
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the vacuum pump. Refer to => [ Vacuum Pump ] Service and Repair.
- Remove the noise insulation. Refer to one of the following:
GTI and Tiguan
Eos and Passat
CC
- Remove the right wheel housing liner..
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the charge air pipe.
- Disconnect the connector - 1 - from the camshaft adjustment valve 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.
- Remove the control valve in the - direction of the arrow - using the assembly tool (T10352).
The control valve has a left hand threads.
- Remove the bolts - arrows - and remove the bearing bracket.
- Rotate the vibration damper using the counter hold tool (T10355) into the Top Dead Center (TDC) position - arrow -.
• The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.
• The marks - 1 - on the camshafts must point upward.
- Apply marks on the camshaft timing chain and the cylinder head - arrows - to match the marks on the sprockets - 1 - using a waterproof marker.
- In addition, apply marks on the camshaft timing chain and the camshaft timing chain guide rail - 2 - using a waterproof marker.
- Remove the plug - arrow -.
- Remove the bolts - arrows -.
- Remove the bolt - arrow -.
Two different chain tensioners may be installed.
Version 1:
- Install the lever (T40243) - arrows -.
- Lift up the locking wedge for the chain tensioner - arrow 1 -. Sand the end of the locking pin (T40011) down to a point. A screwdriver with a head approximately 1.5 mm wide can also be used.
There is a risk of damaging the chain tensioner. Proceed very carefully.
- Slowly press and hold the lever (T40243) in the - direction of arrow 2 -.
- Secure the chain tensioner using the locking pin (T40011).
Version 2:
- Install the lever (T40243) - arrows -.
- Press the chain tensioner lock ring - arrow - together and slowly press and hold the lever (T40243) in the - direction of the arrow -.
- Secure the chain tensioner using the locking tool (T40267).
Continuation for All
- Remove the lever (T40243).
- Bolt the camshaft locating tool (T40271/2) to the cylinder head and push the tool into the sprocket splines in the - direction of arrow 2 -. If necessary, slightly rotate the intake camshaft in the - direction of arrow 1 - using a wrench.
- Bolt the camshaft locating tool (T40271/1) to the cylinder head. Counter hold the camshaft with a wrench in a clockwise direction - arrow -.
- Remove the guide pin - A - and slide the tensioning rail downward while continuing to counter hold the camshaft.
- Rotate the exhaust camshaft further in a clockwise direction - 1 - until the camshaft locating tool (T40271/1) can be pushed into the sprocket splines.
- Remove the upper guide rail - 1 - by unlatching the latch with a screwdriver and pushing the guide rail forward. Mark the position of the sprockets - arrow - to the camshaft locating tools.
- Remove camshaft timing chain from the chain sprockets.
Danger of damaging the valves, piston head and lower timing chain cover.
• Make certain that the timing chain remains tensioned when rotating the crankshaft by hand.
• 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.
If the camshafts are replaced, the previous marks must be transferred. For this reason, the following steps are important:
- Mark the camshaft sprockets to the camshaft locating tools (T40271/1) and (T40271/2) - arrow - before removing the camshafts.
• The following distance gauge indicates whether the marks were transferred correctly later on.
- Measure the distance from the left outer edge of the bar - A - to the mark - B - on the intake camshaft sprocket and write down the value.
- Measure the distance between the mark on the intake camshaft sprocket - B - and the mark on the exhaust camshaft sprocket - C - and write down the value.
- Rotate the intake camshaft in the - direction of arrow 1 - using a wrench, push the camshaft locating tool (T40271/2) out of the sprocket splines in the - direction of arrow 2 - and bring the camshaft into the rest position.
- Rotate the exhaust camshaft in the - direction of arrow 1 - using a wrench, push the camshaft locating tool (T40271/1) out of the sprocket splines if the - direction of arrow 2 - and bring the camshaft into the rest position.
- Remover the ignition coils with the power output stages. Refer to => [ Ignition Coil with Power Output Stage ] Service and Repair.
- Remove the crankcase ventilation bolts - arrows -.
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the charge air pipe bolt - arrow -.
- Loosen the hose clamp - 1 - and remove the charge air pipe together with the crankcase ventilation.
- Disconnect the vacuum line - 1 - and free up the line.
- Disconnect the connector - 2 - from the camshaft position sensor.
- 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
Transfer the self applied marks from the removed camshaft to the new camshaft.
• For the correct tightening specifications, refer to => [ Valvetrain Overview ] Service and Repair.
• Do not start the engine for approximately 30 minutes after installing the camshafts. The hydraulic lash adjusters must seat themselves (otherwise the valves will crash into the pistons).
• After working on the valvetrain and adjusters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.
• 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 tips.
• Note the expiration date of the sealant.
• The cover must be installed within 5 minutes after application of the sealant.
• Prevent dirt and adhesive residue from entering the cylinder head.
- Remove any sealant residue on the cylinder head using a flat blade scraper.
Wear protective eye wear.
- Remove any sealant out of 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 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 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 sealant.
• The sealant bead may not be thicker than specified, otherwise the excess sealant could enter the oil pan and clog the oil suction pipe.
• Note the expiration date of the sealant.
- Tighten the bolts in several stages in sequence, refer to => [ Cylinder Head Cover Bolt Tightening Sequence ] Service and Repair.
• Make sure the cylinder head cover is not tilted.
• Insert the cap - 1 - without sealant using the thrust piece (T10174).
• Dimension - a -: 1 to 2 mm
Danger of damaging the valves, piston head and lower timing chain cover.
• Make certain that the timing chain remains tensioned when rotating the crankshaft by hand.
• 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.
- Rotate the vibration damper using the counter hold tool (T10355) into the TDC position - arrow -.
• The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.
- Rotate the intake camshaft in the - direction of arrow 1 - using a wrench until the mark - 3 - on the sprocket aligns with the camshaft locating tool (T40271/2).
- Push the camshaft locating tool (T40271/2) into the sprocket splines in the - direction of arrow 2 -.
- Rotate the exhaust camshaft in the - direction of arrow 1 - using a wrench, until the mark - 3 -on the sprocket aligns with the camshaft locating tool (T40271/1).
- Push the camshaft locating tool (T40271/1) into the sprocket splines in the - direction of arrow 2 -.
For New Camshafts:
- Compare the distance from the left outer edge of the bar - A - to the mark - B - on the intake camshaft sprocket with the previously noted value.
- Compare the distance between the mark on the intake camshaft sprocket - B - to the mark on the exhaust camshaft sprocket - C - with the previously noted value.
Continuation for All
- Position the marks on the chain links - arrows - to the marks - 1 - on the sprockets and install the camshaft timing chain.
- Install the upper guide rail - 2 -.
• Use the help of a second mechanic to hold the exhaust camshaft in place.
- Slowly rotate the exhaust camshaft in the - direction of arrow 1 - using a wrench, until the camshaft locating tool (T40271/1) can be pushed from the sprocket splines in the - direction of arrow 2 -.
- Carefully release the camshaft, until the camshaft timing chain is laying on the upper guide rail. Hold the camshaft in this position.
- Continue to hold the camshaft and install the camshaft timing chain tensioning rail. Tighten the guide pin - A -.
- Remove the camshaft locating tool (T40271/1).
- Push the camshaft locating tool (T40271/2) out of the sprocket splines in the - direction of arrow 2 -, slightly rotate the intake camshaft in the - direction of arrow 1 - using wrench.
- Remove the camshaft locating tool (T40271/2).
- Check the valve timing. The camshaft timing chain and cylinder head marks - arrows - must align with the marks - 1 - on the sprockets.
- The marks for the camshaft timing chain and the camshaft timing chain guide rail - 2 - must also align with one another.
- The notch on the vibration damper must align with the mark on the lower timing chain cover - 3 -.
• If the self-made marks are no longer visible, check the valve timing, refer to => [ Valve Timing, Checking ] Adjustments.
- Install the bearing bracket. Do not tilt it and install the bolts - arrows - hand tight.
- Remove the locking pin (T40011) or the locking tool (T40267) , depending on the version.
- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Install the bolt - arrow -.
- Install the control valve, see - item 6 - in the => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
• If the mark on the drive chain and guide rail - 2 - do not align even though the engine is at TDC, the drive chain has skipped on the crankshaft sprocket. Check the valve timing. Refer to => [ Valve Timing, Checking ] Adjustments. If the timing does not agree, the camshaft timing chain must be positioned again. Refer to => [ Camshaft Timing Chain (with new tools) ] Camshaft Timing Chain (with new tools).
Further installation is in the reverse order of removal.