Camshafts, removing and installing: Removing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

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 (e.g. for fuel, hydraulic, EVAP system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

Check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
Disconnect battery Ground (GND) strap with ignition switched off.
All cable ties which are opened or cut open when removing, must be replaced in same position when installing.
Remove intake manifold, refer to Cylinder head cover, removing and installing .

Fig 1: Locating Engine Coolant Temperature Sensor G62

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 2-pin connector from Engine Coolant Temperature (ECT) Sensor G62 - arrow -.
Drain coolant, refer to Cooling system, draining and filling under Cooling system, draining and filling .
Remove thermostat housing, refer to Cooling system components (on engine), assembly overview .

Fig 2: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft at vibration damper securing bolt in engine direction of rotation to TDC cyl. 1 - arrow -.
Remove cylinder head cover, refer to Cylinder head cover, removing and installing .

Fig 3: Locating Camshaft Roller Chain Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove camshaft roller chain tensioner - arrow -.
On the following components, pull off the covers for the connectors:

Valve 1 for camshaft adjustment N205
Camshaft adjustment valve 1 (exhaust) N318
Camshaft Position (CMP) sensor G40
Camshaft position (CMP) sensor 2 G163

NOTE:

Before disconnecting harness connectors, mark allocation to component.

Free up wiring harness.
Remove camshaft cover.
Remove exhaust camshaft adjuster.
Remove camshaft adjuster together with camshaft roller chain from intake camshaft.

Fig 4: Locating Counter-Hold Area On Camshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Counter-hold only with 32 mm open end wrench on camshaft - arrow -. Camshaft bar T10068 A must not be installed when camshaft adjuster is loosened or tightened.

Place camshaft roller chain aside.

Fig 5: Locating Control Housing-To-Cylinder Head Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove control housing from cylinder head - arrows -.
Pull control housing carefully off camshaft seals.

Fig 6: Identifying Intake Camshaft And Exhaust Camshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.

Fig 7: Identifying Intake Camshaft And Exhaust Camshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 and remove.

Carefully remove camshafts and place on a clean surface.
Remove roller rocker lever together with support elements and place on a clean surface.
Ensure the roller rocker levers and the support elements are not interchanged.