Removal And Installation: Camshafts

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.

(with cylinder head installed)

Special tools and workshop equipment required

Camshaft bar T10068A
Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332

Removing

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 or vacuum) and electrical wires 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.

-- Check whether a coded radio is installed. If necessary, obtain the antitheft code.

With the ignition switched off, disconnect the battery ground cable. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Bring the lock carrier into the service position. Refer to Description and Operation .

-- All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.

-- 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 thermostat housing. Refer to COOLANT THERMOSTAT HOUSING ASSEMBLY OVERVIEW .

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

NOTE:

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

-- On the following components, pull off the covers for the electrical connectors:

Camshaft adjustment valve 1
Camshaft adjustment valve 1 (exhaust)
Camshaft Position (CMP) sensor
CMP sensor 2

-- Free up the wiring harness.

-- Rotate the crankshaft using the vibration damper bolt in the direction of engine rotation to the Top Dead Center (TDC) cylinder 1 marking -arrow-.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 3: Locating Camshaft Roller Chain Tensioner

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove camshaft cover bolts -arrows-.

Fig 4: Identifying Mounting Bolts For Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First, remove the exhaust camshaft adjuster.

NOTE:

Counter hold only using a 32 mm open end wrench on the camshaft -arrow-. The T10068A must not be inserted when tightening or loosening the camshaft adjuster bolt.

Fig 5: Locating Counter-Hold Area On Camshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove intake camshaft adjuster together with the camshaft roller chain from the intake camshaft.

-- Place the camshaft roller chain aside.

-- Remove the control housing bolts -arrows-.

Fig 6: Locating Control Housing-To-Cylinder Head Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the control housing carefully off of the camshaft seals.

A - Intake Camshaft

Fig 7: Identifying Intake Camshaft And Exhaust Camshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First remove the bearing caps 1 and 13.

-- Remove the bearing caps 3 and 11.

-- Remove bearing cap 7.

-- Loosen and remove bearing caps 5 and 9 in alternation and in a diagonal sequence.

B - Exhaust Camshaft

Fig 8: Identifying Intake Camshaft And Exhaust Camshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First remove bearing caps 2 and 14.

-- Remove bearing caps 4 and 12.

-- Remove bearing cap 8.

-- Loosen bearing caps 6 and 10 in alternation and in a diagonal sequence.

-- Carefully remove the camshafts and place on a clean surface.

-- Remove the roller rocker lever together with support elements and place on a clean surface.

-- Ensure that the roller rocker levers and the support elements are not interchanged.

Installing

Fig 9: Identifying Contact Surfaces Of Bearing Caps 7 And 8

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Requirements

When installing the camshafts, the cam lobes for cylinder 1 must point upward.

-- Install the support element in the cylinder head and install the roller rocker lever onto the respective valve stem end and support element.

-- Make sure that all roller cam followers -1- properly contact the valve stem tips and are clipped into the respective support elements -2-.

Fig 10: Identifying Roller Cam Followers And Support Elements

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lubricate the cam lobes and camshaft running surfaces.

-- Place the respective camshaft carefully in the camshaft bearings of the cylinder head. While doing so, observe the identification of camshafts. Refer to CAMSHAFT IDENTIFICATION AND VALVE TIMING .

NOTE:

Observe the installed position of the bearing caps:

Fig 11: Identifying Points Of Intake And Exhaust Camshaft Bearing Cap Face Outwards

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The points of the intake and exhaust camshaft bearing caps -arrow A- face outwards.

Identification on bearing caps is legible when read from intake side.

A - Intake Camshaft

Fig 12: Identifying Intake Camshaft And Exhaust Camshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bearing caps 5 and 9 alternately and diagonally to 5 Nm + 45° (1/8) additional turn.

-- Install bearing caps 1 and 13 and tighten to 5 Nm + 45° (1/8) additional turn.

-- Install bearing cap 7 and tighten to 5 Nm + 45° (1/8) additional turn.

-- Install bearing caps 3 and 11 and also tighten to 5 Nm + 45° (1/8) additional turn.

B - Exhaust Camshaft

Fig 13: Identifying Intake Camshaft And Exhaust Camshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bearing caps 6 and 10 alternately and diagonally to 5 Nm + 45° (1/8) additional turn.

-- Install bearing caps 2 and 14 and tighten to 5 Nm + 45° (1/8) additional turn.

-- Install bearing cap 8 and tighten to 5 Nm + 45° (1/8) additional turn.

-- Install bearing caps 4 and 12 and also tighten to 5 Nm + 45° (1/8) additional turn.

-- Position the camshafts in the cylinder head to TDC No. 1 cylinder.

-- It must be possible to install the T10068A into both camshaft grooves.

Fig 14: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before installing, check the control housing strainer for contamination. Refer to Figure.

-- Before installing the control housing, lubricate the surfaces in the control housing contacting the camshaft seals.

-- Lubricate the camshaft seals and slowly push the control housing over the camshaft seals.

-- Insert the control housing bolts -arrows- with locking compound and tighten them to 8 Nm.

Fig 15: Locating Control Housing-To-Cylinder Head Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

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

Fig 16: 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 using sealant D 176 501 and install the sealant D 176 501 onto the sealing surfaces of the timing chain cover.

-- Install the timing chain cover immediately.

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

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

-- Install the sealant D 176 501 onto sealing surface of the timing chain cover and install immediately.

-- First install all bolts and lightly tighten.

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