Camshafts and Camshaft Adjusters, Removing and Installing
Camshafts and camshaft adjusters, removing and installing
Removing
Installing
Special tools, testers and auxiliary items required
^ Holder for chain tensioner 3366
^ Torque wrench (5 to 50 Nm) V.A.G 1331
^ Sealant AMV 188 001 02
Removing
- Set engine to TDC Toothed belt, removing, installing and tensioning.
- Remove the toothed belt and camshaft gear Toothed belt, removing, installing and tensioning, Toothed belt, removing, installing and tensioning.
Left cylinder head
- Remove the cylinder head cover Left cylinder head cover, removing and installing.
- Unscrew bolts - 1 - and - 2 - and remove rear toothed belt cover.
Right cylinder head
- Remove the cylinder head cover Right cylinder head cover, removing and installing.
- Remove the idler roller - 1 -.
- Unscrew bolts - arrows - and remove rear toothed belt cover.
Continuation for both cylinder heads
- Disconnect the connector from the Hall sender and remove the Hall sender housing with cover and cone.
- Verify TDC position of camshafts. The markings on the camshafts must be aligned with both arrows on the bearing cap - arrows -.
When re-using the camshaft roller chain:
- Mark roller chain - arrows - before removing (e.g. with paint, arrow pointing in direction of rotation).
Note:
^ Do not mark chain with a center punch or similar means!
- Secure camshaft adjuster with bracket for chain adjustment 3366.
Note:
^ If the bracket for chain adjustment is fastened too tightly, the camshaft adjuster can be damaged.
- Independent of existing markings, mark the installed position and sequence of all bearing caps as shown (e.g. with a water-proof felt pen).
- Remove mounting bolts of camshaft adjuster.
- Remove bearing cap - 1 -.
- Remove bearing caps - 2 -, - 4 -, - 6 -, - 8 - and - 9 - and lay on a clean surface in correct order.
- Loosen bearing caps - 3 -, - 5 - and - 7 - alternately in a diagonal sequence, and remove.
- Remove both camshafts with camshaft adjusters and place on a clean surface.
Installing
- Replace the half-round sealing plugs.
- Replace the seal for the camshaft adjuster.
- Lightly coat the shaded area with the sealant AMV 188 001 02.
- Place the camshaft roller chain onto the camshaft drive sprockets as follows.
When re-using the camshaft roller chain:
- Move the color markings to congruency - arrows -.
When re-using a new camshaft roller chain:
The distance between the notches - A - and - B - must consist of 16 rollers on the drive chain. Illustration shows where - 1 - and - 16 - drive chain rollers must be installed on chain sprockets. The chain rollers - 1 - and - 16 - are across from notches - A - and - B -, and are respectively a 1/2 tooth width offset to the left.
Continued
- Push camshaft adjuster in between the camshaft roller chain.
- Install camshafts with camshaft roller chain and camshaft adjuster into cylinder head.
- Oil journal surfaces of camshafts.
Note:
^ Alignment bushings for bearing caps and camshaft adjusters must be installed in cylinder head.
- Install bearing caps - 3 -, - 5 - and - 7 - according to markings and fasten new bolts alternately in a diagonal sequence. Torque specification: 5 Nm + 1/4 turn (90°)
- Tighten the camshaft adjuster - 10 -. Torque specification: 5 Nm + 1/4 turn (90°)
- Install the chain tensioner.
- Verify TDC position of camshafts. The markings on the camshafts must be aligned with both arrows on the bearing cap - arrows -.
Note:
^ So that both markings line up, turn camshaft slightly back and forth if necessary.
- Lightly coat the double bearing cap - 6 - and the bearing cap - 1 - with sealant AMV 188 001 02 and install the bearing caps. Torque specification: 5 Nm + 1/4 turn (90°)
- Install the remaining bearing caps. Torque specification: 5 Nm + 1/4 turn (90°)
- Replace the camshaft seals Camshaft seals, replacing.
- Replace the seals for the Hall sender Hall sender seals, replacing.
- Carefully drive in the sealing cover with the pressure piece of the retractor 3202.
The rest of the assembly is reverse of removal
Note:
- After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).
- After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.
Lightly coat separation surfaces of front and rear bearing caps with grease AMV 188 001 02 before installing