Removal And Installation: Camshafts

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. 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-
Sealant -D 154 103 A1-

NOTE:

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

The camshaft bearings are integrated in the cylinder head or 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 in the same location.

Removing

-- 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 front part of the right wheel housing liner and/or the right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Remove the bolts -arrows-.

Fig 1: Identifying Air Guide Pipe And Bolts

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-- Lift the clamps -1 and 2- and remove the charge air pipe.

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

Fig 2: Identifying Camshaft Adjustment Valve And Bolts

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

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

CAUTION:

The control valve has left hand threads.

-- Remove the control valve in the -direction of the arrow- using the assembly toolT10352.

Fig 3: Identifying Assembly Tool T10352 To Remove Control Valve

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

Fig 4: Identifying Bearing Bracket Bolts

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-- Rotate the vibration damper to the Top Dead Center (TDC) position -arrow- using the counter hold tool -T10355-.

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

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The notch on the vibration damper must line up with the arrow mark -arrow- on the lower timing chain cover.
The marks -1- on the camshafts must point upward.

-- Carefully mark the position of the drive chain to the sprockets -A arrows- with a waterproof marker. Also mark the position of the drive chain to the guide rail -B arrows-. These marks are necessary for reinstallation.

Fig 6: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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-- Remove the plug -arrow-.

Fig 7: Locating Plug

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The locking wedge in the chain tensioner must be lifted in order to release the tension from the chain tensioner. Grind 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.

CAUTION:

There is a risk of damaging the chain tensioner. Proceed very carefully.

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

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

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-- In order to tension the chain tensioner, rotate the crankshaft opposite the engine rotation direction -2- and secure it 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

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-- Remove the upper guide rail -3- by unlocking the latch located in the center 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.

Make certain that the timing chain remains tensioned when turning 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.

-- Disconnect the connectors from the ignition coils and free up the wiring harness.

-- Remove the ignition coils using the ignition coil puller -T40039-.

Fig 10: Identifying Ignition Coil Puller T40039 To Remove Ignition Coils

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

Fig 11: Identifying Crankcase Ventilation, Tightening Sequence

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-- Remove the bolts -arrows-.

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

Fig 12: Identifying Charge Air Pipe Bolt -Arrow- And Hose Clamp -2-

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

Fig 13: Identifying Camshaft Position Sensor G40 Electrical Connector And Lines

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

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

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

Fig 14: Identifying Cylinder Head Cover Loosening

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-- 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 rocker arms make contact correctly on the valve stem ends.

Note the expiration date of the silicone sealant.

The cover must be installed within 5 minutes after application of the silicone sealant.

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

WARNING:

Wear safety glasses.

NOTE:

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.

Fig 15: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

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

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-- Lubricate the running surfaces of both camshafts.

-- Place the camshaft into the cylinder head, the recesses -arrows- must be perpendicular to each other.

Fig 17: Identifying Camshaft Recesses

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-- Replace the cylinder head cover bolts.

-- Apply the silicone sealant -D 154 103 A1- on the clean sealing surface of the cylinder head cover as shown -arrows-.

Fig 18: Identifying Cylinder Head Cover Sealing Surface

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Thickness of sealant bead: 2 to 3 mm.

NOTE:

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

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

Note the expiration date of the sealant.

-- Tighten the bolts in several passes in the tightening sequence, refer to Figure.

NOTE:

Make sure the cylinder head cover is not tilted.

Instal the cap -1- without sealant using the thrust piece -T10174-.

Fig 19: Identifying Thrust Piece T10174 To Drive In Cap

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Dimension -a- : 1 to 2 mm

CAUTION:

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

Make certain that the timing chain remains tensioned when turning 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 to the TDC position -arrow- using the counter hold tool -T10355-.

Fig 20: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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

-- Mount the timing chain on the intake camshaft. The marks must align.

Fig 21: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

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-- Rotate the intake camshaft in the -direction of the arrow- with a wrench until the timing chain is taut. Hold the intake camshaft secure in this position.

-- Mount the timing chain on the exhaust camshaft: The marks on the drive chain and sprocket -A arrows- and the drive chain and guide rail -B arrows- must line up with each other.

Fig 22: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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-- Install the upper guide rail -3-.

Fig 23: Identifying Guide Tensioning Rail, Upper Guide Rai And Bolt

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-- Move the tensioning rail -2- up and tighten the guide pin -1-.

NOTE:

If the marks on the drive chain and guide rail -B arrows- 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 . If the timing does not agree, the camshaft timing chain must be positioned again. Refer to CAMSHAFT TIMING CHAIN .

Fig 24: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

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The rest of the installation is basically a reverse of the removal sequence.