Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft housing

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Dial gauge adapter -T10170-

t	Camshaft clamp -T10171-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Spark plug spanner -3122 B-

t	Torque wrench (5...50 Nm) -V.A.G 1331-

Removing   Note t  The camshaft housing sealing surface must not be reworked. t  Removing and installing camshafts → Chapter –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  With ignition switched off, disconnect battery earth strap.

–  Remove camshaft housing cover by removing bolts -arrows-. –  Press locking devices -1- and pull air intake connecting piece out of air intake guide.

–  Remove spring-type clamp -2- using hose clip pliers -VAS 6340- or spring-type clip pliers -VAS 5024A-. –  Remove bolts for exhaust camshaft cover -3- and inlet camshaft cover -4- and pull covers out of camshaft housing.

–  Pull connector off oil pressure switch -F1--1-, Hall sender -G40--2- and camshaft adjustment valve 1 -N205--4-. –  Remove both lifting eyes -3-.

–  Install left lifting eye -3- on cylinder head using bolts (M8 x 25) -1- and nuts (M10) -2-.   Note t  If the cylinder head is to be removed, follow procedure for removing and installing cylinder head → Chapter t  The nuts (M10) are used to increase the distance between the lifting eye and the camshaft housing so that the camshaft housing can be removed and installed. Specified torque: 20 Nm

–  Install support device -10 - 222 A- with adapter -10 - 222 A /1- as shown and hook into lifting eye -arrow-. –  Remove valve timing housing → Chapter. –  Turn crankshaft to TDC no. 1 cylinder. Then turn crankshaft back 45° against engine direction and remove camshaft timing sprockets with timing chain → Chapter –  Remove ignition coils. Use puller -T10094 A- for this purpose → Chapter. –  Remove cable guide with wiring harness from camshaft housing. –  Pull out oil dipstick. –  Loosen camshaft housing bolts from outside to inside, alternately and diagonally and remove. –  Carefully lift camshaft housing off. Installing Prerequisite l  The pistons must not be positioned at TDC. –  Remove sealant residue on camshaft housing and cylinder head with a rotating brush, e.g. a hand drill with a plastic brush (wear eye protection). –  Prevent dirt and residual sealant from entering cylinder head. –  Clean sealing surfaces carefully. They must be free of oil and grease.

–  Turn inlet and exhaust camshafts until camshaft clamp -T10171- can be pushed into holes in camshaft to stop. –  Secure camshaft clamp -T10171- with an M6 bolt hand tight (do not tighten).

–  Apply a thin, even coat of sealant to clean camshaft housing sealing surface. See hatched area on illustration.   Note The sealant must not be applied too thick; otherwise excess sealant can enter the oil channels and cause damage to the engine.

–  Ensure that all roller rocker fingers contact valve stem ends -1- correctly and that they are clipped into their respective support elements -2-. –  Screw two studs (M6x80) into cylinder head before installing camshaft housing.

–  Carefully fit camshaft housing vertically onto cylinder head studs -arrows- and dowel pins from above.   Note Ensure that no oil residue can drip onto sealing surfaces. –  Evenly tighten new camshaft housing securing bolts from inside to outside alternately and diagonally. Ensure that camshaft housing is not canted. Torque setting: 10 Nm + 1/4 turn (90°) further.   Note Sealant must dry for approx. 30 minutes after camshaft housing is installed. –  Adjust valve timing → Chapter. –  Install valve timing housing → Chapter. Further assembly is basically the reverse of the dismantling procedure.