Camshaft: Service and Repair
Camshafts, removing and installing
(with cylinder head installed)
Special tools and equipment
^ T10068 Camshaft bar
^ V.A.G 1331 Torque wrench (5...50 Nm)
^ V.A.G 1332 Torque wrench (40...200 Nm)
^ AMV 174 004 01 Sealing compound
^ AMV 188 001 02 Sealing compound
^ G 052 723 A2 Grease
Removing
CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: All cable ties which are opened or cut open during disassembly, must be replaced in the same position during installation
- Remove engine cover.
- Check whether a coded radio is fitted. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove intake manifold, Refer to Timing Cover, Service and Repair
- Pull 4-pin connector -arrow- off Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-.
- Drain coolant.
- Remove coolant thermostat housing.
- Set crankshaft to TDC No. 1 Cyl marks -arrow- by turning crankshaft on vibration damper securing bolt in engine direction of rotation.
- Remove cylinder head cover.
- Remove camshaft roller chain tensioner -arrow-.
- Disconnect connections from following components on cover:
^ Camshaft Position (CMP) sensor -G40- -1-,
^ Camshaft Position (CMP) sensor 2 -G163- -2-,
^ Valve 1 for camshaft adjustment -N205- -3-,
^ Camshaft adjustment valve 1 -N318- -4-.
Note: Mark connector and component before disconnecting connector.
- Release and free wiring harness.
- Remove camshaft cover.
- Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation).
Note: Do not mark chain with a punched mark, notch or similar!
- First remove exhaust camshaft timing adjuster.
- Remove camshaft timing adjuster together with camshaft roller chain from intake camshaft.
Note: Counter-support on camshaft with a 32 mm open end wrench -arrow-. Camshaft bar T10068 must not be fitted when loosening or tightening the camshaft timing adjuster.
- Place camshaft roller chain to side.
- Remove control housing from cylinder head -arrows-.
- Pull control housing carefully of camshaft seals.
A - Intake camshaft
- First remove bearing caps 1 and 13.
- Remove bearing caps 3 and 11.
- Remove bearing cap 7.
- Loosen bearing caps 5 and 9 alternately and diagonally, and remove.
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 diagonally.
- Carefully remove camshafts and place on a clean surface.
- Remove roller rocker finger together with support elements and place on a clean surface.
Note: Ensure the roller rocker fingers and the support elements are not interchanged.
Installing
Conditions
^ When camshafts are installed, No. 1 Cyl. cams must point upward.
^ The pistons must not be positioned at TDC.
- Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end / support element.
- Ensure that all roller rocker fingers -1- are properly fitted onto valve stem ends and are clipped onto respective support elements -2-.
- Oil running surfaces of camshafts.
- Place respective camshaft carefully into camshaft bearings in cylinder head. Observe marks on camshafts, Refer to Cylinder Head, Service and Repair, Valve Gear Servicing, See Fig 5.
Note: Observe installation position of bearing caps:
^ Points of bearing caps -arrow A- of intake and exhaust camshafts face outward.
^ Identifications on bearing caps are legible when read from intake side.
A - Intake camshaft
- Lubricate hatched contact surface of bearing cap 7 from both sides lightly with grease G 052 723 A2 before installation, Refer to Cylinder Head, Service and Repair, Valve Gear Servicing, See Fig 2.
- Tighten bearing caps 5 and 9 alternately and diagonally to 5 Nm and 1/8 turn (45°)
- Install bearing caps 1 and 13 and tighten to 5 Nm and 1/8 turn (45°)
- Install bearing cap 7 and tighten to 5 Nm and 1/8 turn (45°)
- Install bearing caps 3 and 11 and tighten to 5 Nm and 1/8 turn (45°)
B - Exhaust camshaft
- Lubricate hatched contact surface of bearing cap 8 from both sides lightly with grease G 052 723 A2 before installation, Refer to Cylinder Head, Service and Repair, Valve Gear Servicing, See Fig 2.
- Tighten bearing caps 6 and 10 alternately and diagonally to 5 Nm and 1/8 turn (45°)
- Install bearing caps 2 and 14 and tighten to 5 Nm and 1/8 turn (45°)
- Install bearing cap 8 and tighten to 5 Nm and 1/8 turn (45°)
- Install bearing caps 4 and 12 and tighten to 5 Nm and 1/8 turn (45°)
- Position camshafts in cylinder head to TDC No. 1 cylinder.
Camshaft bar T10068 must engage in both shaft grooves.
Note: If the camshaft bar cannot be engaged in the camshafts, turn camshafts in direction of rotation past TDC No. 1 Cyl/. and then back to TDC No. 1 Cyl.
- Before installing, check screen in control housing for soiling.
- Before installing control housing, lightly lubricate contact surfaces in control housing for camshaft seals.
- Lubricate contact surfaces of camshaft seals lightly and slowly push control housing over camshaft seals.
- Install control housing -arrows- and tighten to 8 Nm.
- Remove old sealing compound from 3 mm holes in cylinder head gasket -arrows-.
Note: When the cylinder head is installed the holes in the cylinder head gasket are only half visible.
The rest of the assembly is basically in reverse order to the disassembling sequence.
Note: Ensure that the O-ring for sealing the oil channel and the seal in the cover are fitted.
- Adjust valve timing, Refer to Timing Components, Adjustments
- Install cylinder head cover and intake manifold, Refer to Timing Cover, Service and Repair.
- Check camshaft adjustments, Refer to Camshaft,Engine, Adjustment.