CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
3.2
Removing and installing camshaft
Special tools and workshop
equipment required
♦ Assembly tool - T10352-
♦ Engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB:
assembly tool - T10352/1-
♦ Counter-hold tool - T10355-
♦ Pin - T40011-
♦ Assembly lever - T40243-
♦ Locking tool - T40267-
♦ Camshaft clamp - T40271-
3. Valve gear
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♦ Thrust piece - T10174-
♦ Puller - T40039-
♦ Silicone sealant - D 154 103 A1-
Note
♦ Sealing surfaces at bottom of cylinder head cover and top of
cylinder head must not be machined.
♦ Camshaft bearings are integrated in cylinder head and in cyl‐
inder head cover. The camshaft timing chain must be relieved
of tension before you remove the cylinder head cover.
♦ Renew sealing cap if cylinder head cover has been detached
⇒ Item 15 (page 184) .
♦ Fit cable ties in the original positions when installing.
Removing:
– Pull off engine cover panel ⇒ page 141 .
– Remove vacuum pump ⇒ page 180 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Unscrew bolts -arrows-.
– Remove air pipe (lift clips -items 1 and 2-).
– Pull off connector -1- from camshaft control valve 1 - N205- .
– Unscrew bolts -arrows- and remove inlet camshaft control
valve 1 - N205- .
– Remove upper timing chain cover ⇒ page 91 .
– Remove control valve using assembly tool - T10352- (engine
codes CCZA, CCZB, CDAA, CDAB: assembly tool -
T10352/1- ) in -direction of arrow-.
Caution
The control valve has a left-hand thread.
– Remove bolts -arrows- and detach bearing saddle.
3. Valve gear
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– Turn vibration damper to “TDC” position -arrow- using coun‐
terhold - T10355- .
•
Notch on vibration damper must align with arrow marking on
cover for timing chains (bottom).
•
The markings -1- on the camshafts must face upwards.
– Mark positions of sprocket markings -1- on camshaft timing
chain and cylinder head -arrows- using a permanent felt tip
marker.
– Also mark alignment of camshaft timing chain -2- relative to
guide rail of camshaft timing chain using a permanent felt tip
marker.
– Remove sealing plug -arrow-.
– Unscrew bolts -arrows-.
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Unscrew bolt -arrow-.
Depending on version, either of two different chain tensioners
may be installed. Version 1:
– Screw in lever - T40243- -arrows-.
Note
♦ If it is not possible to insert the lever - T40243- , the distance
between the timing chain and the oil deflector on the lower
cover is too small. It is then necessary to remove the lower
cover.
♦ Passat, CC ⇒ page 93
♦ Golf, Eos, Scirocco ⇒ page 99
♦ Tiguan ⇒ page 106
– Raise locking element of chain tensioner -arrow 1-. To do this,
grind the tip of the locking pin - T40011- to a point. A screw‐
driver with a blade width of approx. 1.5 mm can also be used.
Caution
Avoid damage to chain tensioner! Proceed with great care.
– Slowly push valve lever - T40243- in -direction of arrow 2- and
hold it in that position.
– Secure chain tensioner with locking pin - T40011- .
3. Valve gear
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Version 2:
– Screw in lever - T40243- -arrows-.
Note
♦ If it is not possible to insert the lever - T40243- , the distance
between the timing chain and the oil deflector on the lower
cover is too small. It is then necessary to remove the lower
cover.
♦ Passat, CC ⇒ page 93
♦ Golf, Eos, Scirocco ⇒ page 99
♦ Tiguan ⇒ page 106
– Press together securing clip -arrow- of chain tensioner. Then,
slowly push lever - T40243- in -direction of arrow- and hold it
in that position.
– Secure chain tensioner with locking pin - T40267- .
All
– Remove lever - T40243- .
– Bolt camshaft clamp - T40271/2- to cylinder head and insert it
in direction of arrow -2- between teeth of sprocket. If necessary
turn inlet camshaft slightly in direction of arrow -1- using span‐
ner.
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Bolt camshaft clamp - T40271/1- to cylinder head. Counter‐
hold camshaft clockwise -arrow- using open-end spanner.
– Remove bolt -A- and take out tensioning rail downwards. In
the process, continue to counterhold the camshaft.
– Turn exhaust camshaft clockwise -1- until camshaft clamp -
T40271/1- can be inserted into sprocket splines.
– Use screwdriver to release catch and press off top guide rail
-1- forwards. Mark position of sprockets -arrow- relative to
camshaft clamp.
– Remove camshaft timing chain from camshaft sprockets.
Caution
Risk of damaging valves, piston crowns and lower timing chain
cover.
♦ Ensure the timing chain is always under tension when
turning the crankshaft.
♦ Plates to prevent the chain falling down are attached to
the lower timing chain cover. If the crankshaft is turned
when the chain is loose, the plates may bend.
3. Valve gear
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If the camshafts are renewed, the markings which you applied
earlier must be transferred. To do so, proceed as follows:
– Before removing camshafts, mark alignment of camshaft
sprockets relative to camshaft clamp - T40271/1- and cam‐
shaft clamp - T40271/2- -arrow-.
Note
The following measurement of distances is later used to check
whether the markings have been correctly transferred.
– Measure distance from left outer edge of web -A- to marking
-B- on inlet camshaft and record figure.
– Measure distance from marking on inlet camshaft -B- to mark‐
ing on exhaust camshaft -C- and record figure.
– Turn inlet camshaft in -direction of arrow 1- using spanner,
remove camshaft clamp - T40271/2- in -direction of arrow 2-
from between teeth of sprocket and bring camshaft into rest
position.
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Turn exhaust camshaft in -direction of arrow 1- using spanner,
remove camshaft clamp - T40271/1- in -direction of arrow 2-
from between teeth of sprocket and bring camshaft into rest
position.
– Removing ignition coils with output stages ⇒ page 562 .
Engine codes CCZA, CCZB, CDAA, CDAB:
– Separate crankcase breather hoses -1 and 2-.
– Remove bolts -arrows- and remove crankcase breather.
Engine codes CBFA, CCTA:
– Disconnect crankcase breather hose -1-.
– Unscrew bolts -arrows-.
– Unscrew bolt -arrow- for air pipe.
– Loosen hose clip -1- and remove air pipe together with crank‐
case breather.
3. Valve gear
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All:
– Disconnect vacuum line -1- and move line to one side.
– Detach and remove electrical connector -2- from Hall sender
- G40- .
– Undo and remove cylinder head cover bolts in the sequence
-1 … 6-.
– Remove cylinder head cover.
– Detach camshafts.
– Prevent dirt and residual sealant from entering cylinder head.
Installing camshafts
If new camshafts are to be fitted, transfer the markings which you
made on the removed camshafts to the new ones.
•
Specified torques ⇒ page 182
Note
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
♦ Sealing surfaces must be free of oil and grease.
♦ The pistons cannot be positioned at TDC.
♦ Ensure that all roller rocker fingers are properly seated on
valve stem ends.
♦ Note expiry date of silicone sealant.
♦ The cover must be installed within 5 minutes after applying the
silicone sealant.
♦ Prevent dirt and residual sealant from entering cylinder head.
– Remove sealant remaining on cylinder head with flat scraper.
WARNING
Wear protective goggles.
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Remove sealant left in groove of cylinder head cover and on
sealing surfaces, e.g. using a rotating plastic brush.
– Clean sealing surfaces. They must be oil and grease free.
– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2
mm).
– Oil running surfaces of both camshafts.
– Install camshafts in cylinder head. Recesses -arrows- must be
vertical to each other.
– Renew bolts for cylinder head cover.
– Apply silicone sealant - D 154 103 A1- onto clean sealing sur‐
face of cylinder head cover, as illustrated -arrows-.
♦ Thickness of sealant bead: 2 to 3 mm.
Note
♦ The cylinder head cover must be installed within 5 minutes
after applying the silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
♦ Check the expiry date of the sealant.
– Tighten bolts in several stages; tightening sequence
⇒ page 184 .
3. Valve gear
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Note
♦ Take care to keep cylinder head cover level.
♦ Use thrust piece - T10174- to drive in sealing cap -1- without
sealant.
♦ Dimension -a-: 1 to 2 mm
Caution
Risk of damaging valves, piston crowns and lower timing chain
cover.
♦ Ensure the timing chain is always under tension when
turning the crankshaft.
♦ Plates to prevent the chain falling down are attached to
the lower timing chain cover. If the crankshaft is turned
when the chain is loose, the plates may bend.
– Turn vibration damper to »TDC« position -arrow- using coun‐
terhold - T10355- .
•
Notch on vibration damper must align with arrow marking on
cover for timing chains (bottom).
– Turn inlet camshaft in -direction of arrow 1- until marking -3-
aligns with camshaft clamp - T40271/2- .
– Insert camshaft clamp - T40271/2- into teeth of sprocket -2-.
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Turn exhaust camshaft in direction of arrow -1- until marking
-3- aligns with camshaft clamp - T40271/1- .
– Insert camshaft clamp - T40271/1- in -direction of arrow 2- be‐
tween teeth of sprocket.
Procedure for new camshafts:
– Compare distance from left outer edge of web -A- to marking
-B- with figure recorded earlier.
– Compare distance from marking on inlet camshaft -B- to mark‐
ing on exhaust camshaft -C- with figure recorded earlier.
Continued for all:
– Fit camshaft timing chain on sprockets. To do this, align mark‐
ings on chain links -arrows- with markings on sprockets -1-.
– Install upper guide rail -2-.
Note
Have a second mechanic hold the exhaust camshaft.
3. Valve gear
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– Slowly turn exhaust camshaft in direction of arrow -1- until
camshaft clamp - T40271/1- can be withdrawn from sprocket
teeth.
– Carefully relieve load on camshaft until camshaft timing chain
lies against upper guide rail. Hold camshaft in this position.
– Continue to hold camshaft and install tensioning rail for cam‐
shaft timing chain. Tighten bolt -A-.
– Remove camshaft clamp - T40271/1- .
– Slide camshaft clamp - T40271/2- out of sprocket teeth -2-, if
necessary turning inlet camshaft slightly using spanner -1-.
– Remove camshaft clamp - T40271/2- .
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4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Check valve timing. Markings on camshaft timing chain and
cylinder head -arrows- must align with markings on sprockets
-1-.
– Markings on camshaft timing chain and on guide rail of cam‐
shaft timing chain -2- must also align.
– Notch on vibration damper must align with marking on lower
timing chain cover -3-.
Note
If the previously marked markings are no longer visible, check
valve timing ⇒ page 135 .
– Fit bearing saddle carefully. Do not cant bearing saddle! Screw
in bolts -arrows- and tighten by hand.
– Depending on version, remove locking pin - T40011- or locking
tool - T40267- .
– Tighten bolts -arrows- for bearing saddle ⇒ page 112 .
– Screw in bolt -arrow-.
– Install control valve ⇒ Item 6 (page 113) .
Note
If the markings on the camshaft timing chain and the guide rail
-2- no longer align even though the engine is at »TDC«, the drive
chain may have jumped on the crankshaft sprocket. Check valve
timing ⇒ page 135 If the timing is not correct, the camshaft timing
chain has to be taken off and fitted »again« ⇒ page 114 .
Further assembly is basically a reverse of the dismantling se‐
quence.
3. Valve gear
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3.3
Checking axial clearance of camshafts
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
Test sequence
– Perform measurement with retaining frame removed.
– Fit camshaft to be tested in retaining frame.
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
•
Axial clearance: 0.05 to 0.17 mm
3.4
Renewing valve stem seals
⇒ “3.4.2 Removing and installing valve stem seals (cylinder head
removed)”, page 205
3.4.1
Removing and installing valve stem seals (cylinder head installed)
200
Rep. gr.15 - Cylinder head, valve gear
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
