Camshaft Adjuster Valves

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque wrench (5-60 Nm) VAG 1783
TORX® bit set VAG 1766
Ratchet insert 1/4" VAS 6234
Socket wrench T10072

Removing

-- Remove the intake manifold. Refer to INTAKE MANIFOLD .

-- Disconnect the 2 pin electrical connector -arrow- from the Engine Coolant Temperature (ECT) sensor.

Fig 1: Identifying Engine Coolant Temperature (ECT) Sensor G62 Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- Remove the coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING ASSEMBLY OVERVIEW .

-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Disconnect the Secondary Air Injection (AIR) pressure hoses -item 18- in the SECONDARY AIR INJECTION SYSTEM COMPONENTS ASSEMBLY OVERVIEW .

NOTE:

Before disconnecting the harness electrical connectors, mark the allocation to the component.

-- Disconnect the electrical connectors from the Camshaft Position (CMP) sensor -1- and the CMP sensor 2 -2-.

Fig 2: Identifying CMP Sensor G40, CMP Sensor 2 G163 And Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the electrical connectors -3 and 4-.

-- Free up the wiring harness.

-- Remove the camshaft roller chain tensioner -arrow-.

Fig 3: Locating Camshaft Roller Chain Tensioner

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the timing chain cover bolts -arrows-.

Fig 4: Identifying Mounting Bolts For Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- When all the bolts have been removed, the cover can be carefully pried off.

CAUTION:

Do not completely remove the camshaft adjustment valve bolts so that the valve is not tilted when removed.
Carefully cover the lower chain compartment so no parts can fall in.

-- Loosen the camshaft adjustment valve bolts approximately 3 mm (5 turns) -arrows- using T10072.

Fig 5: Identifying Camshaft Adjustment Valve Securing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the camshaft adjustment valves out of the seal seat in the control housing against the loosened bolts.

-- Completely remove the bolts and remove the camshaft adjustment valves from the control housing.

Installing

CAUTION:

The valve seat in the control housing must not be scored or scratched.
The camshaft adjustment valves and control housing must be free of dust and contamination.
The camshaft adjustment valves must not be subjected to knocks or impacts.
Only remove the new camshaft adjustment valve from the packaging right before installation.
The camshaft adjustment valves must not be pulled into the valve seat by the bolts. Only press them in by hand.

-- Lubricate the sealing rings with clean engine oil.

-- Carefully insert the camshaft adjustment valve into the housing and press it perpendicular to the valve axle by hand until seated.

-- Tighten the bolts -arrows- to 3.8 Nm.

Fig 6: Identifying Camshaft Adjustment Valve Securing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-1- Camshaft adjustment valve 1.

-2- Camshaft adjustment valve 1 (exhaust).

-- Clean the sealing surface on the timing chain cover as well as on the cylinder head.

-- Lubricate the oil channel seal O-ring -item 13- in the CYLINDER HEAD AND COVER ASSEMBLY OVERVIEW , and insert it in the cover.

-- Insert the seal -item 20- in the CYLINDER HEAD AND COVER ASSEMBLY OVERVIEW , into the timing chain cover.

-- Clean the old sealing compound from the 3 mm holes in the cylinder head gasket -arrows-.

Fig 7: Locating 3 mm Holes In Cylinder Head Gasket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Fill the 3 mm holes the in the cylinder head gasket with sealant D 176 501 and install the sealant D 176 501on the sealing surfaces of the timing chain cover.

NOTE:

With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

-- Install the timing chain cover as quickly as possible.

-- Install the timing chain cover bolts -arrows- and tighten lightly.

Fig 8: Identifying Mounting Bolts For Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the M8 bolts -item 8- in TIMING CHAIN COVER ASSEMBLY OVERVIEW to 23 Nm and tighten the M6 bolts -item 2- in TIMING CHAIN COVER ASSEMBLY OVERVIEW to 8 Nm.

-- Install the camshaft roller chain tensioner -item 15- in the CYLINDER HEAD AND COVER ASSEMBLY OVERVIEW and tighten it to 40 Nm.

-- Install the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Install the intake manifold. Refer to INTAKE MANIFOLD .

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