Camshaft: Service and Repair
Camshafts
(With Cylinder Head Installed)
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Sealant (D 176 501 A1)
• Adhesive lubricating paste (G 052 723 A2)
Removing
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.
- See if a coded radio is installed. If so, obtain the anti-theft code.
Disconnect the battery Ground (GND) cable with the ignition turned off.
- Bring lock carrier into service position.
- All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Disconnect the 2-pin connector from the Engine Coolant Temperature (ECT) sensor (G62) - arrow -.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the thermostat housing. Refer to => [ Coolant Thermostat Housing Overview ] Coolant Thermostat Housing Overview.
- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Remove chain tensioner- arrow - for camshaft timing chain.
- Remove the following connectors:
• Camshaft adjustment valve 1 (N205)
• Exhaust camshaft adjustment valve 1 (N318)
• Camshaft Position (CMP) sensor (G40)
• CMP sensor 2 (G163)
• Mark the connector assignment to the component before disconnecting the connectors.
- Free up the wiring harness.
- Remove the front camshaft cover bolts - arrows - and cover.
- First, remove the exhaust camshaft adjuster.
• Counter hold the camshaft on the recesses - arrow - using a 32 mm open end wrench. (T10068 A) must not be installed when tightening or loosening the camshaft adjuster bolts.
- Remove the camshaft adjuster and the camshaft timing chain from the intake camshaft.
- Place the camshaft timing chain to the side.
- Remove the control housing bolts - arrows - from cylinder head.
- Pull control housing carefully off camshaft seals.
A - Intake Camshaft
- First remove bearing caps 1 and 13.
- Remove bearing caps 3 and 11.
- Remove bearing cap 7.
- Loosen and remove bearing caps 5 and 9 in alternately and in a diagonal sequence.
B - Exhaust Camshaft
- First remove bearing caps 2 and 14.
- Remove bearing caps 4 and 12.
- Remove bearing cap 8.
- Loosen bearing caps 6 and 10 in alternately and in diagonal sequence.
- Carefully remove camshafts and place on a clean surface.
- Remove 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
Lightly apply lubricating paste (G 052 723 A2) to the contact surfaces of bearing caps 7 and 8 before installing
Requirements
• When installing the camshafts, the cam lobes for cylinder 1 must point upward.
- Install the support elements in the cylinder head and install the roller rocker levers onto their respective valve stem end and support element.
- Make sure that all roller rocker levers - 1 - properly contact the valve stem tips and are clipped into the respective support elements - 2 -.
- Lubricate the camshaft lobes and camshaft running surfaces.
- Place the respective camshaft carefully in the camshaft bearings in the cylinder head. While doing so, observe the identification of the camshafts. Refer to => [ Camshaft Identification, Valve Timing ] Service and Repair.
• Observe the installed position of the bearing caps:
• The points - arrow A - on the intake and exhaust camshaft bearing caps face outward.
• Identification on bearing caps is legible when read from intake side.
A - Intake Camshaft
- Tighten the bearing caps 5 and 9 alternately and diagonally to 5 Nm + 45° (1/8) additional turn.
- Install the bearing caps 1 and 13 and tighten them to 5 Nm 45° (1/8) additional turn.
- Install the bearing cap 7 and tighten them to 5 Nm 45° (1/8) additional turn.
- Install the bearing caps 3 and 11 and tighten them to 5 Nm 45° (1/8) additional turn.
B - Exhaust Camshaft
- Tighten the bearing caps 6 and 10 alternately and diagonally to 5 Nm 45° (1/8) additional turn.
- Install the bearing caps 2 and 14 and tighten them to 5 Nm 45° (1/8) additional turn.
- Install the bearing cap 8 and tighten them to 5 Nm 45° (1/8) additional turn.
- Install the bearing caps 4 and 12 and tighten them to 5 Nm 45° (1/8) additional turn.
- Position the camshafts in the cylinder head to TDC No. 1 cylinder. The camshaft lobes - A - for cylinder 1 must face each other.
- It must be possible to install the (T10068 A) into both camshaft grooves.
- Before installing, check the control housing strainer for contamination. Refer to => [ Control Housing, Checking Strainer for Contaminants ] Service and Repair.
- 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.
- Install the control housing bolts - arrows - using locking adhesive (D 000 600 A2). Tightening specification: 8 Nm.
- Install the camshaft adjustors with timing chain. Refer to => [ Camshaft Adjuster with Camshaft Timing Chain, Installing ] Camshaft Adjuster with Camshaft Timing Chain, Installing.
- Clean the sealing surfaces on the cover and on the cylinder head.
- Lubricate oil passage seal O-ring - 1 - and insert it in the cover.
- Make sure the alignment sleeves - 2 and 3 - are installed.
- Install the seal - 4 - in the cover.
- Clean the old sealing compound from the 3 mm holes in the cylinder head gasket - arrows -.
- Fill the 3 mm holes in the cylinder head gasket with sealant (D 176 501 A1). Apply sealant (D 176 501 A1) to the sealing surfaces on the cover and install the cover immediately.
- Install the camshaft front cover bolts - arrows - and tighten lightly.
- Then tighten the M8 bolts => [ (Item 8) Bolt ] Service and Repair to 23 Nm and tighten the M6 bolts => [ (Item 2) Stud bolt ] Service and Repair to 8 Nm.
- Install the chain tensioner for the camshaft timing chain => [ (Item 15) Chain Tensioner ] Cylinder Head and Cover Overview and tighten to 40 Nm.
- Install the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Install the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.