Removal And Installation: Camshafts

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment 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
Silicone sealant D 154 103 A1
Cable Ties
Flat Scraper
Hand Drill with Plastic Brush Attachment
Protective Eyewear

Removing

NOTE:

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 the 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.

All cable ties which are opened or cut off 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 and vacuum) and electrical wiring 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 .

-- Remove the vacuum pump. Refer to VACUUM PUMP .

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the right front wheel.

-- Remove the front part of the right wheel housing liner and/or the entire right front wheel housing liner. Refer to Removal and Installation .

-- Remove the bolts -arrows-.

Fig 1: Identifying Air Guide Pipe And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Disconnect the connector -1- from camshaft adjustment valve 1 -N205-.

Fig 2: Identifying Camshaft Adjustment Valve And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER .

CAUTION:

The control valve has a left hand threads.

-- Remove the control valve using the assembly Tool T10352 in the -direction of the arrow-

Fig 3: Identifying Assembly Tool T10352 To Remove Control Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Identifying Bearing Bracket Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use the counter hold Tool T10355 to rotate the vibration damper to Top Dead Center (TDC) -arrow- :

Fig 5: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 6: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the plug -arrow-.

Fig 7: Locating Plug

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 8: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Rotate the crankshaft opposite the engine rotation direction -arrow direction 2- and secure the tensioner using a locking pin T40011.

NOTE:

The intake camshaft switches in the engine rotation direction.

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

Fig 9: Identifying Guide Tensioning Rail, Upper Guide Rai And Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

When the lower timing chain cover is installed, the loose chain on the crankshaft cannot 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 from the cylinder head, then the crankshaft must not be rotated 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 COIL WITH POWER OUTPUT STAGE , and lay the wiring harness to the side.

Fig 10: Identifying Crankcase Ventilation, Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the bolts -arrows-.

-- Remove the charge air pipe bolt -arrow-.

Fig 11: Identifying Charge Air Pipe Bolt -Arrow- And Hose Clamp -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 12: Identifying Camshaft Position Sensor G40 Electrical Connector And Lines

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

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

Fig 13: Identifying Cylinder Head Cover Loosening

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 .

NOTE:

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

The pistons must not be positioned at TDC.

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

Note the expiration date of the silicone sealant.

The cylinder head cover must be installed within 5 minutes after applying the silicone sealant.

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

WARNING:

Risk of eye injury.

Wear protective eyewear.

NOTE:

Prevent dirt and adhesive residue from entering the cylinder head.

-- 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.

Fig 14: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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).

Fig 15: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lubricate the running surfaces of both camshafts.

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

Fig 16: Identifying Camshaft Recesses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Replace the cylinder head cover bolts.

-- Apply the silicone sealant to the clean sealing surface of the cylinder head cover as shown -arrows-.

Fig 17: Identifying Cylinder Head Cover Sealing Surface

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Thickness of sealant bead: 2 to 3 mm.

NOTE:

The cylinder head cover must be installed within 5 minutes after applying the silicone sealant.

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

Note the expiration date of the sealant.

-- Tighten the bolts in several steps:

Tightening sequence and specification, refer to Figure.

NOTE:

Make sure the cylinder head cover is not tilted.

-- Insert the cap -1- without sealant using the thrust Piece T10174:

Fig 18: Identifying Thrust Piece T10174 To Drive In Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Dimension -a- = 1 to 2 mm.

CAUTION:

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

-- Use the counter hold Tool T10355 to rotate the vibration damper to TDC -arrow- :

Fig 19: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

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

-- Install the camshaft timing chain:

Fig 20: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marked drive chain/sprockets -arrows- must align.

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

Further installation is in the reverse order of removal.