Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft adjuster   Note Renewing camshaft timing chain → Chapter. Special tools and workshop equipment required

t  Camshaft bar -T10068 A- t  Black sealant → Electronic parts catalogue t  Sealing paste → Electronic parts catalogue Removing camshaft adjuster –  Remove cylinder head cover → Chapter. –  Remove thermostat housing → Chapter.

–  Remove hose -3- and vacuum hose -2- from combi-valve for secondary air system. –  Pull coolant hose -1- off.

–  Mark and detach electrical connectors: 1 -  Hall sender -G40- 2 -  Hall sender 2 -G163- 3 -  Inlet camshaft control valve 1 -N205- 4 -  Exhaust camshaft control valve 1 -N318- –  Unbolt cable guide from camshaft timing chain cover.

–  Set crankshaft to TDC No. 1 cylinder marking -arrow- by turning crankshaft on the vibration damper securing bolt in direction of engine rotation.

–  Cams -A- of cylinder 1 must face each other.

–  Insert camshaft bar -T10068 A- in both shaft grooves. If necessary, move the camshafts back and forth slightly with an open-end spanner.

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

–  Undo and remove bolts -1 … 3- and pull cover off cylinder head horizontally. When doing so, ensure that cylinder head gasket is not damaged. –  Remove camshaft bar -T10068 A-.   Note Make sure that the camshaft bar -T10068 A- has not been fitted when the securing bolt for camshaft adjuster is being loosened or tightened.

–  Mark chain links that are opposite the markings on the camshaft adjusters. Installation is facilitated by marking the camshaft timing chain.

–  Unscrew bolt for camshaft adjuster approx. 1 turn at outlet end, using an open-ended spanner to counterhold on flat side of camshaft.

–  Unscrew bolt for camshaft adjuster approx. 1 turn at inlet end, using an open-ended spanner to counterhold on flat side of camshaft.

–  Insert camshaft bar -T10068 A- in both shaft grooves. If necessary, move the camshafts back and forth slightly with an open-end spanner. –  Remove camshaft adjuster. –  Lay camshaft timing chain over the valves for camshaft adjustment.

Installing camshaft adjuster Prerequisite l  Crankshaft -arrow- is at »TDC« position.

l  Cams -A- of cylinder 1 face each other.

l  The camshaft bar -T10068 A- has been placed in the two shaft grooves.   Note

Both camshaft adjusters (marking: „24E“ on inlet side and „32A“ on exhaust side) can be screwed at camshaft mounting in one position only -arrows- due to a dowel pin.

–  Now turn sender wheel -1- on removed inlet camshaft adjuster to right stop in -direction of arrow- and hold adjuster in this position.   Note

If the inlet camshaft adjuster -A- is bolted to the camshaft, turn the adjuster with chain sprocket to the left accordingly and then fit the camshaft timing chain.

–  Ensure the camshaft timing chain is »tight« against the guide rail -1- and does not »sag«. It must be possible to easily position adjuster and tighten it hand-tight with camshaft timing chain positioned »tautly« on inlet camshaft.

l  „Arrow“-1- on the camshaft adjuster of the inlet camshaft must align with the left notch -2- on the control housing. Markings on valve timing housing → Fig.

–  Now, from the tooth that is aligned with the „24E“ marking, count exactly 16 rollers on the timing chain to the right. Mark this roller with a coloured pen.   Note The exhaust camshaft adjuster is locked when »at rest«. This prevents the sender wheel from turning when adjusting the valve timing. If the locking mechanism is not engaged (locked) when »at rest«, turn the adjuster in both directions by hand until it is locked. If this is not possible, renew camshaft adjuster.

–  Insert exhaust camshaft adjuster „32A“ into camshaft timing chain with tooth on marking -1- so that the previously counted 16 rollers lie precisely between marking „24E“ and „32A“, and markings -1- and -2- align. –  It must be possible to easily position the exhaust camshaft adjuster onto the exhaust camshaft and tighten it hand-tight.

–  Check the position of both camshaft adjusters again to ensure the setting is correct. –  Remove camshaft bar -T10068 A-.   Note

So that the camshaft timing chain does not jump a tooth when the crankshaft is turned, the tensioner plate must be pressed against the camshaft timing chain by hand instead of with chain tensioner. –  Turn crankshaft two full turns in direction of engine rotation and check valve timing → Chapter.

If the markings align: –  Hold camshaft which is to be tightened using a 32 mm open-end spanner -arrow-.   Note Camshaft bar -T10068 A- must be removed while this is done. –  Tighten securing bolts of inlet and exhaust camshaft adjusters to 60 Nm + 90° (1/4 turn) further. If seals in cover are to be renewed → Fig.. –  Clean sealing surface 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 and tighten to 40 Nm. –  Turn crankshaft two full turns in direction of engine rotation and check valve timing again. –  Install cylinder head cover and intake manifold → Chapter.