Camshaft Adjuster Valves

Camshaft Adjuster Valves

Special tools, testers and auxiliary items required

• Socket Wrench (T10072)

• TORX Bit Set (V.A.G 1766)

• Torque Wrench (5-60 Nm) (V.A.G 1783)

• Ratchet Insert 1/4" (VAS 6234)

Removing

- 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.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

• Mark the connector assignment to the component before disconnecting the connectors.

- Disconnect the connectors from the Camshaft Position (CMP) sensor (G40) - 1 - and CMP sensor 2 (G163) - 2 -.






- Disconnect connectors - 3 - and - 4 -.

- Free up the wiring harness.

- Remove camshaft timing chain tensioner - arrow -.






- Remove the camshaft front cover bolts - arrows -.






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


• Do not completely remove camshaft adjustment valve bolts so that valve is not tilted when removed.

• Carefully cover lower chain compartment so no parts can fall in.

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






- Pull the camshaft adjustment valve 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


• 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 new camshaft adjustment valve from packaging right before installation.

• Camshaft adjustment valves must not be pulled into valve seat by the bolts. Only press them in by hand.

- Lubricate the seals with clean engine oil.

- Carefully install the camshaft adjustment valve into the housing and press it in perpendicular to the valve axis by hand until its seated.

- Install and tighten the bolts - arrows - to 3.8 Nm.






- 1 - Camshaft adjustment valve 1 (N205).

- 2 - Exhaust camshaft adjustment valve 1 (N318).

- Clean the sealing surfaces on the cover and on the cylinder head.

- Lubricate the oil passage seal O-ring - 1 - and insert it in the cover.






- Make sure the alignment sleeves - 2 and 3 - are inserted.

- 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.






- 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 and the intake manifold => [ Intake Manifold ] Intake Manifold.

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