Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft control valves

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1783-

t	Torx bit set -V.A.G 1766-

t	1/4" drive ratchet -VAS 6234-

t	Special wrench, long reach -T10072-

Removing: –  Remove intake manifold → Chapter.

–  Pull off 2-pin connector from coolant temperature sender -G62--arrow-. –  Drain coolant → Chapter. –  Remove thermostat housing → Chapter. –  Remove cylinder head cover → Chapter.   Note Before removing connectors, mark each connector and component to which it belongs.

–  Pull connectors off Hall sender -G40--1- and Hall sender 2 -G163--2-. –  Pull off connectors -3- and -4-. –  Move wiring harness clear.

–  Remove chain tensioner for camshaft timing chain -arrow-.

–  Unscrew securing bolts -arrows- for cover. –  Cover can be prised off carefully when all securing bolts have been removed.   Caution t  In order to make sure that valves do not become jammed when they are being removed, do not completely unscrew securing bolts of camshaft control valves. t  Cover lower chain housing carefully so that no parts can fall into it.

–  Unscrew securing bolts for camshaft control valves approx. 3 mm (5 turns) with socket -T10072--arrows-. –  Pull camshaft control valve out of seat in control housing and slide it along loosened bolts. –  Completely remove securing bolts and pull camshaft control valve out of control housing. Installing:   Caution t  The valve seat in the control housing must not be scored or scratched. t  The camshaft control valves and the control housing must be free of dirt and soiling. t  Ensure the camshaft control valves are protected from knocks and impacts. t  Only unpack the new camshaft control valves immediately prior to installation. t  The camshaft control valves must not be pulled into their seat with the securing bolts. Only insertion by hand is permitted. –  Moisten seals with clean engine oil. –  Carefully insert camshaft control valve into housing and push vertically to valve axis to stop by hand.

–  Tighten securing bolts -arrows- to 3.8 Nm. -1-Camshaft control valve 1 -N205-. -2-Exhaust camshaft control valve 1 -N318-. –  Clean sealing surface a on cover and cylinder head.

–  Lubricate O-ring for oil channel seal -1- and insert in cover. –  Check that dowel sleeves -2- and -3- are inserted. –  Insert O-ring -4- in cover.

–  Remove old sealant from 3 mm holes in cylinder head gasket -arrows-. –  Fill 3 mm holes in cylinder head gasket with sealant -D 176 501 A1-. Coat sealing surface of cover with sealant -D 176 501 A1- and immediately install.

–  First insert all securing bolts -arrows- and tighten lightly. –  Then tighten M8 securing bolts → Item to 23 Nm and M6 securing bolts → Item to 8 Nm. –  Install chain tensioner for camshaft timing chain → Item and tighten to 40 Nm. –  Install cylinder head cover → Chapter and intake manifold → Chapter. Further assembly is basically the reverse of the dismantling sequence.