Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft adjuster Special tools and workshop equipment required

t  Camshaft bar -T10068- t  Sealant, black -AMV 174 04 01- t  Sealing paste -AMV 188 001 02- Removing –  Remove intake manifold → Chapter. –  Drain coolant → Chapter.

–  Detach air hose -4- and vacuum hose -1- from combination valve for secondary air system. –  Unbolt earth wire -2-. –  Pull off coolant hoses -3- and -5-.

–  Mark and detach electrical connectors: 1 -  Hall sender -G40- 2 -  Hall sender 2 -G163- 3 -  Inlet camshaft adjuster valve 1 -N205- 4 -  Exhaust camshaft adjuster valve 1 -N318-

–  Loosen cylinder head cover bolts in sequence -11 … 1-.

–  Set crankshaft at securing bolt of vibration damper in direction of engine rotation to TDC marking -arrow-.

–  At same time it must be possible to insert camshaft bar -T10068- in both shaft grooves. If necessary, turn crankshaft through 1 rotation.

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

–  Unscrew bolts -1 … 3- and remove top cover for timing chains horizontally from cylinder head. When doing so, ensure that cylinder head gasket is not damaged. –  Remove camshaft bar -T10068-.   Note Make sure that the camshaft bar -T10068- is not inserted when the retaining bolts for the camshaft adjuster are being loosened or tightened.

–  Unscrew retaining bolt on inlet camshaft adjuster, counterholding hexagon section of camshaft with 32 mm open-end spanner. –  Remove inlet camshaft adjuster.

–  Unscrew retaining bolt on exhaust camshaft adjuster, counterholding hexagon section of camshaft with 32 mm open-end spanner. –  Remove exhaust camshaft adjuster. –  Place camshaft timing chain over camshaft adjuster valves.

Installing (adjusting valve timing) –  Check TDC position of crankshaft -arrow- again.

–  Check TDC position of camshafts: l  The camshaft bar -T10068- must engage in grooves in both shafts.

–  If necessary, turn camshafts -arrows- to correct position using 32 mm open-end spanner on hexagon sections.   Note Ensure that crankshaft is not at TDC with any piston when camshafts are turned. Danger of damage to valves and piston crowns.

–  Screw on inlet camshaft adjuster -A- and turn to left as far as stop.

l  Contact surface of sender wheel must be dry around bolt head when installed. l  Mark „24E“-item 1- and tooth behind it -2- must align with notch -3- in valve timing housing. –  Place camshaft timing chain in this position tight on sprocket of inlet camshaft adjuster.

–  From mark „24E“ of inlet camshaft adjuster count exactly 16 rollers on timing chain in direction of exhaust side. –  Insert tooth at mark „32A“ of exhaust camshaft adjuster into chain exactly after 16th roller. l  There must now be 16 chain rollers between the teeth. l  Here, too, mark „32A“ and tooth behind it must align with notch in valve timing housing.

–  Turn sender wheel-2- in exhaust camshaft adjuster -1- clockwise as far as stop -arrow-. –  Hand-tighten exhaust camshaft adjuster to exhaust camshaft in this position. l  Contact surface of sender wheel must be dry around bolt head when installed.

–  Press tensioning plate against camshaft timing chain.

Check setting marks of camshaft adjusters against marks on control housing: –  Marks -A- and -B- on camshaft adjusters must align with notches -arrows- in valve timing housing -C-. If the marks match, the further assembly process can continue.

–  Remove camshaft bar -T10068-. –  Tighten retaining bolt on inlet camshaft adjuster, counterholding hexagon section of camshaft with 32 mm open-end spanner.

–  Tighten retaining bolt on exhaust camshaft adjuster, counterholding hexagon section of camshaft with 32 mm open-end spanner.   Note

When turning the crankshaft, the tensioning plate must be pressed firmly against the camshaft timing chain by hand (instead of by means of the chain tensioner) -arrow-, to prevent the chain from jumping.

–  Rotate crankshaft through 2 turns at vibration damper securing bolt in direction of engine rotation and set to to TDC mark -arrow-.

–  At same time It must be possible to insert camshaft bar -T10068- in both shaft grooves.

Re-check setting marks of camshaft adjusters against marks on control housing: –  Marks -A- and -B- on camshaft adjusters must align with notches -arrows- in valve timing housing -C-. –  If marks do not match, repeat setting process for timings.

–  Remove old sealant from 3 mm holes in cylinder head gasket -arrows-. –  Fill 3 mm holes in cylinder head gasket with black sealant -AMV 174 04 01-.   Note With the cylinder head installed, the holes in the cylinder head gasket are only half visible. –  Fit new seals in top cover for timing chains → Fig.. –  Clean sealing surfaces. l  They must be free of oil and grease.

–  Check whether dowel sleeves -2- and -3- are inserted in top cover for timing chains. –  Fit new seal -1- and new gasket -4-. –  Coat clean -hatched- sealing surfaces of top cover for timing chains thinly with sealing paste -AMV 188 001 02-.   Note t  Also coat sealing surface underneath cylinder head gasket with a little sealant, taking care not to kink cylinder head gasket. t  The top cover for the timing chains must be fitted within 5 minutes of applying the sealant.

–  Locate top cover for timing chains and tighten bolts as follows. 1 -  Tighten bolts -1- and -2- to 5 Nm. 2 -  Tighten bolts -3- to 23 Nm. 3 -  Tighten bolts -1- and -2- to 10 Nm.

–  Unscrew chain tensioner -arrow- for camshaft timing chain. –  Turn engine two revolutions in direction of engine rotation and check valve timing again. –  Install cylinder head cover → Chapter. –  Install intake manifold → Chapter. –  Install thermostat housing → Chapter. Specified torques

Component		Nm
Guide rail to cylinder block		10
Camshaft adjuster to camshafts		60 + 90° → Remark → Remark
Top cover for	M6	10
camshaft timing chain	M8	23
Chain tensioner for camshaft timing chain to top cover for timing chains		40

1)  Renew bolt. 2)  90° equals a quarter of a turn