VW Passat & Audi A4 1990-2000

Camshaft, Bearings & Lifters

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The camshaft and cylinder hear are precision machined components. Both the camshaft lobes and journals are hardened to provide long service life and reliability. The cylinder head(s) used on the A4 and Passat models covered in this guide are a cast aluminum alloy. The camshaft bearing journals are machined into the cylinder head and Do NOT have replaceable bearings.

The cylinder head camshaft journal bearing caps and journals are align-bored during production of the cylinder head. If removed, they must be reinstalled in exactly the same location and direction from which they were removed. The bearing cap fasteners must be tightened evenly using several steps until the specified torque specification is reached.

The lifters are installed into machined bores in the cylinder head and are located underneath the camshaft and rest on top of the valve and valve spring assembly. The lifters are hydraulic and Do NOT require periodic adjustment. If removed, they must be reinstalled in exactly the same location from which they were removed.

Both the hydraulic lifters and camshaft journals are lubricated by engine oil which is pressure fed via the engine oil pump through a series of oil galleys that are machined into the cylinder head.

removal & installation

WARNING
The camshaft is relatively brittle and must be removed and installed carefully otherwise it will break.

1990-97 Passat Models
2.0L DOHC 16V (9A) Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover.
  4.  
  5. Remove the upper intake manifold and cylinder head cover.
  6.  
  7. Turn the engine to TDC on cylinder No. 1, then slacken and remove the timing belt and camshaft sprocket.
  8.  
  9. Using a felt marker or touch up paint, matchmark the timing chain to the camshafts for reinstallation and note its direction of rotation.
  10.  
  11. Remove the camshaft chain.
  12.  
  13. On the intake camshaft, remove bearing caps Nos. 5 and 7 and the chain end cap. Then loosen bearing caps Nos. 6 and 8 alternately and diagonally.
  14.  
  15. On the exhaust camshaft, remove bearing caps Nos. 1 and 3 and the end caps. Then loosen bearing caps Nos. 2 and 4 alternately and diagonally.
  16.  
  17. Remove the remaining bearing cap bolts and remove the camshafts.
  18.  

To install:

  1. Lubricate the camshaft bearing journals with fresh engine oil and lubricate the camshaft lobes with a suitable pre-assembly lubricant and set the camshafts in place. Install the camshaft drive chain so the marks on the chain sprockets are matched at the base of the cylinder head, directly across from each other.
  2.  


NOTE
When installing the bearing caps, make sure the notch points towards the intake side of the head.

  1. On the intake camshaft, install and torque bearing caps Nos. 6 and 8 alternately and diagonally to 11 ft. lbs. (15 Nm).
  2.  
  3. Install and torque the remaining intake camshaft bearing caps.
  4.  
  5. On the exhaust camshaft, torque bearing caps Nos. 2 and 4 alternately and diagonally to 11 ft. lbs. (15 Nm).
  6.  
  7. Install and torque the remaining exhaust camshaft bearing caps. Camshaft shaft endplay on both camshafts should be about 0.006 inches (0.15mm).
  8.  
  9. Install the drive sprocket and timing belt.
  10.  
  11. Install remaining parts in reverse order of removal. Wait at least 1 / 2 hour after installing camshaft shafts before starting the engine to allow the hydraulic lifters to leak down.
  12.  

2.0L SOhc 8v (aba) engine
  1. Disconnect the negative battery cable. Remove the timing belt cover(s), the timing belt, cylinder head cover and the camshaft sprocket.
  2.  
  3. Number the bearing caps from front to back. If the cap does not already have one, scribe an arrow pointing towards the front of the engine. The caps are offset and must be installed correctly. Factory numbers on the caps are not always on the same side.
  4.  
  5. Remove the front and rear bearing caps. Loosen the remaining bearing cap nuts a little at a time to avoid bending the camshaft. Start from the outside caps near the ends of the head and work toward the center.
  6.  
  7. Remove the bearing caps and the camshaft.
  8.  



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Fig. Remove the nuts and washers noting their exact position



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Fig. Notice that some of the camshaft bearing caps have an integral nut/washer assembly



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Fig. Lift the bearing caps straight off the studs. Do NOT rock the caps side to side or the studs may bend



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Fig. Inspect the camshaft bearing caps for wear



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Fig. Lift the camshaft straight up once all the caps have been freed



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Fig. After all the caps have been removed and placed in their correct position on a marked sheet of paper, remove the camshaft



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Fig. Lubricate the hydraulic lifter. . .



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Fig. . . . then install it into the cylinder head



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Fig. Lifters reinstalled in the head in their correct positions

To install:

  1. Install a new oil seal and end plug in the cylinder head. Lubricate the camshaft bearing journals and lobes and set the camshaft in place.
  2.  
  3. Install the bearing caps in the correct position with the arrow pointing towards the front of the engine. Tighten the cap nuts diagonally and in several steps until they are torqued to 15 ft. lbs. (20 Nm). Do NOT over torque. Camshaft shaft endplay should be about 0.006 inches (0.15mm).
  4.  
  5. Install the drive sprocket and timing belt. Wait at least 1 / 2 an hour after installing camshaft shaft before starting the engine to allow the lifters to leak down.
  6.  
  7. The balance of the installation is in reverse order of removal.
  8.  

2.8L vr6 engine

This procedure requires the use of a camshaft alignment plate, Tool No. 3268 or its equivalent to hold the camshafts at Top Dead Center (TDC) for cylinder No. 1 during installation of the timing chains.

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the engine trim panels.
  4.  
  5. Remove the ignition wires and wire guide as an assembly.
  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Remove the cylinder head cam cover.
  10.  
  11. Rotate the crankshaft to TDC of No. 1 piston.
  12.  
  13. Remove the timing chain tensioner bolt and the upper timing chain cover.
  14.  
  15. Mark the direction of travel on the upper camshaft drive chain with paint or a suitable marker. Do NOT scratch the surface or use a punch. Remove the tensioner shoe and the chain.
  16.  
  17. Counter-hold the camshafts at the flats with a 24mm ( 15 / 16 inch) wrench and remove the bolts to remove the sprockets.
  18.  


WARNING
Do NOT use the setting tool to hold the camshafts when removing or installing the sprocket bolts. The camshafts or the tool will be damaged.

  1. On the long camshaft, remove the end bearing caps. Loosen the center cap nuts in a diagonal pattern 2 turns at a time until the valve springs are relieved. Remove the camshaft.
  2.  
  3. On the short camshaft, remove the center bearing cap and loosen the nuts on the end-caps in a diagonal pattern 2 turns at a time. When the valve springs are relieved, remove the camshaft.
  4.  



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Fig. Hold the camshafts with an open-end wrench on the flats (arrows) when removing or installing the sprocket bolts

To install:

  1. Lubricate the long camshaft and the cylinder head bearing surfaces with fresh engine oil and set the camshaft in place. Place the camshaft at TDC for cylinder No.1. Install bearing cap Nos. 3 and 5 and tighten the bolts 2 turns at a time in a diagonal pattern to draw the camshaft down against the valve springs.
  2.  
  3. Install the other bearing caps and tighten all the nuts to 15 ft. lbs. (20 Nm).
  4.  
  5. Repeat the process with the short camshaft, placing the camshaft at TDC for cylinder No.1, and use bearing cap Nos. 2 and 6 to draw the camshaft down against the springs.
  6.  
  7. Make sure the camshafts are at TDC for cylinder No.1. The valves should be closed and the toe of the cam pointing upward away from the hydraulic lifters. If the camshafts must be moved and the lower cover and double roller chain installed, support the double roller chain using and an assistant if necessary. Rotate the engine away (opposite direction of operation) from TDC about 45-90°, then carefully turn the camshafts making sure the valves Do NOT collide until properly positioned. Once properly positioned carefully rotate the crankshaft to TDC.
  8.  


NOTE
If the crankshaft is correctly positioned, the TDC alignment notch on the intermediate shaft should be at the top most position.

  1. Install the camshaft alignment plate, Tool No. 3268, or its equivalent.
  2.  
  3. Install the tensioning plate pivot pins and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the tensioning plate for the double chain tensioner, then install locating pin with the collar for guide rail and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Place the guide rail on the locating pin, then insert the short securing bolt using a locking agent and tighten both bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. If removed, install the double chain onto the intermediate shaft gear making sure if not replaced, the chain is installed in its original direction of rotation.
  10.  
  11. Fit the camshaft sprocket and the double chain to the camshaft for cylinder Nos. 2, 4 and 6 (the shorter camshaft) and hand tighten the sprocket bolt.
  12.  
  13. Install the camshaft sprocket along with the Camshaft Position (CMP) Sensor wheel and the double roller chain onto the camshaft for cylinder Nos. 1, 3 and 5 and hand tighten.
  14.  


NOTE
Make sure that the contact surfaces of the timing chain and sensor wheel are dry when installing and to oil the contact surfaces of bolts during installation.

  1. Remove the camshaft alignment tool.
  2.  
  3. Counter-hold each camshaft using a 24 mm ( 15 / 16 ) open-end wrench installed on the cast in hex portion of the camshaft. Tighten both camshaft sprocket mounting bolts to 74 ft. lbs. (100 Nm).
  4.  


WARNING
The camshaft alignment tool must not be installed when tightening or loosening the sprocket bolts.

  1. Clean and coat sealing surfaces of the upper timing chain cover housing with a sealant such as Part No. AMV 188 001 02.
  2.  
  3. Install the cover onto the engine using new O-rings, coating the smaller O-ring with a light film of fresh engine oil. Lightly tighten the mounting bolts.
  4.  
  5. Tighten the M8 cover bolts to 18 ft. lbs. (25 Nm), then tighten the M6 bolts to 88 inch lbs. (10 Nm).
  6.  
  7. If the chain tensioner has pulled apart, bleed chain tensioner using a small, sturdy wire to relieve the check ball and collapse the tensioner. If the tensioner expands again, repeat the procedure.
  8.  
  9. Install the double chain tensioner into the housing with a new seal and tighten to 22 ft. lbs. (30 Nm).
  10.  
  11. Turn the crankshaft carefully two full revolutions in the normal running direction and verify the valve timing before attempting to start or before engine installation.
  12.  
  13. Install the cylinder head cover, upper intake manifold and ignition system components.
  14.  
  15. The balance of installation is in reverse order of removal.
  16.  

A4 & 1998-00 Passat Models
1.8L Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the engine trim covers.
  8.  
  9. Remove timing belt upper cover.
  10.  
  11. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at Top Dead Center (TDC).
  12.  
  13. Using Torx® wrench T45, loosen the timing belt tensioner.
  14.  
  15. Push down on the tensioner, and remove the belt from the camshaft gear.
  16.  
  17. Remove the Torx® bolt and swing the tensioner assembly bracket forward.
  18.  
  19. Remove the valve cover.
  20.  
  21. Using retainer tool No. 3036 or equivalent, loosen the cam gear retaining bolt.
  22.  
  23. Remove the camshaft gear.
  24.  
  25. Remove the housing for Camshaft Position (CMP) sensor and shutter wheel.
  26.  
  27. Secure the hydraulic chain tensioner with bracket tensioner tool No. 3366 or equivalent.
  28.  
  29. Verify that the camshafts are at Top Dead Center (TDC) for the No. 1 cylinder. Both camshaft markings must align with arrows on the bearing caps.
  30.  
  31. Clean the drive chain and the cam chain gears opposite both arrows on the bearing caps. Matchmark the installed position using paint.
  32.  


NOTE
The distance between the 2 arrows/paint marks is equivalent to 16 drive chain rollers, and the notch on the exhaust camshaft is slightly offset inward toward the drive chain roller.

  1. Remove the bearing caps 3 and 5 from the intake and exhaust camshafts.
  2.  
  3. Remove the double bearing cap.
  4.  
  5. Remove both bearing caps from the chain gears on the intake and exhaust camshafts.
  6.  
  7. Remove the hydraulic chain tensioner retaining bolts.
  8.  
  9. In an alternating and diagonal sequence, loosen the bearing caps 2 and 4 of the intake and exhaust manifold, then remove.
  10.  
  11. Remove the camshafts with the hydraulic chain tensioner.
  12.  



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Fig. Exploded view of the camshaft mounting and related components-1.8L Engine



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Fig. Do NOT overtighten the chain tensioner tool No. 3366, or equivalent, it can be damaged-1.8L and 2.8L V6 DOHC Engines



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Fig. To ensure proper installation, matchmark the chain-to-camshaft position-1.8L and 2.8L V6 DOHC Engines



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Fig. Camshaft bearing cap identification-1.8L Engine



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Fig. To ensure a proper seal, be sure to apply sealant to the hatched area-1.8L and 2.8L V6 DOHC Engines

To install:


CAUTION
After installing the lifters or the camshaft(s), the engine must NOT be started for at least 30 minutes. Otherwise the valves could strike the pistons. Rotate the engine by hand, at least 2 revolutions, to ensure that the valves Do NOT strike the pistons.

  1. Replace the rubber/metal chain tensioner gasket and apply sealant to the hatched area, as shown.
  2.  
  3. Install the drive chain on the camshaft as follows:
  4.  
    1. If installing the old chain, align the paint marks with the camshaft marks.
    2.  
    3. If installing a new chain, the distance between the notches "A" and "B" on the camshafts must equal the distance between 16 drive chain rollers.
    4.  

  5. Slide the hydraulic chain tensioner between the drive chain.
  6.  
  7. Install the camshafts with the chain tensioner into the cylinder head.
  8.  
  9. Oil the camshaft contact surfaces.
  10.  


NOTE
When installing the bearing caps, verify the markings on the caps are readable from the intake side of the cylinder head.

  1. Tighten the bearing caps 2 and 4 of the intake and exhaust camshafts in an alternating diagonal sequence to 84 inch lbs. (10 Nm).
  2.  
  3. Install both bearing caps on the chain sprockets of the intake and exhaust camshafts and tighten to 84 inch lbs. (10 Nm).
  4.  
  5. Verify the correct positions of the camshafts.
  6.  
  7. Remove the bracket tensioner.
  8.  
  9. Lightly coat the cylinder head mating surface of the double bearing cap with sealant, then install.
  10.  
  11. Install the remaining bearing caps and tighten to 84 inch lbs. (10 Nm).
  12.  
  13. Install the camshaft gear and tighten the retaining bolt to 48 ft. lbs. (65 Nm).
  14.  
  15. Install the Camshaft Position (CMP) shutter wheel and housing cover.
  16.  
  17. Install the valve cover.
  18.  
  19. Align the camshaft gear and the vibration damper with the TDC markings.
  20.  
  21. Install the timing belt.
  22.  
  23. Install the accessory drive belts, then the engine cover.
  24.  
  25. Reinstall the lock carrier.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  30.  
  31. Check the oil level before starting the engine
  32.  
  33. Set the clock to the correct time.
  34.  
  35. Enter the radio security code.
  36.  


NOTE
Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  
  3. Adjust the headlights.
  4.  

2.8L V6 SOHC Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the engine trim covers.
  8.  
  9. Remove the timing belt.
  10.  
  11. Remove the valve cover(s).
  12.  
  13. On the left cylinder head, remove the Camshaft Position Sensor (CMP).
  14.  
  15. On the right cylinder head, remove the plug/cover on the head.
  16.  
  17. Remove the camshaft timing belt sprocket.
  18.  
  19. Identify the bearing caps.
  20.  


NOTE
Do NOT allow the bearing caps to become mixed up.

  1. Remove the camshaft bearing cap Nos. 2 and 3.
  2.  
  3. Gradually and evenly, loosen the nuts for the camshaft bearing cap Nos. 1 and 4, in a diagonal sequence.
  4.  
  5. Remove the cam and lift out the valve lifter. If it is to be reused, it must go in the bore from which it was removed.
  6.  



Click image to see an enlarged view

Fig. Camshaft bearing cap identification-2.8L V6 SOHC Engine

To install:

  1. Install the lifters into their respective bore.
  2.  
  3. Install bearing cap Nos. 1 and 4 in a alternating and diagonal sequence.
  4.  
  5. Install bearing cap Nos. 2 and 3, then tighten all bearing caps to 15 ft. lbs. (20 Nm).
  6.  


CAUTION
After installing the lifters or the camshaft(s), the engine must NOT be started for at least 30 minutes. Otherwise the valves could strike the pistons. Rotate the engine by hand, at least two revolutions, to ensure that the valves Do NOT strike the pistons.

  1. Install the camshaft timing belt sprocket and tighten the mounting bolt to 52 ft. lbs. (71 Nm).
  2.  
  3. On the right cylinder head, install the plug/cover on the head.
  4.  
  5. On the left cylinder head, install the Camshaft Position Sensor (CMP) and tighten the mounting bolts to 88 inch lbs. (10 Nm).
  6.  
  7. Install the valve cover.
  8.  
  9. Install the timing belt.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  14.  
  15. Check the oil level before starting the engine
  16.  
  17. Set the clock to the correct time.
  18.  
  19. Enter the radio security code.
  20.  


NOTE
Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  
  3. Check and adjust the headlights.
  4.  

2.8L V6 DOHC Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the engine trim covers.
  8.  
  9. Rotate the engine to Top Dead Center (TDC).
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the valve cover(s).
  14.  
  15. Properly relieve the fuel system pressure.
  16.  
  17. Remove the engine lower splash shield.
  18.  
  19. Remove the crankshaft housing ventilation line from the cylinder head cover.
  20.  
  21. Remove the intake air duct.
  22.  
  23. Remove the coolant expansion tank and place aside.
  24.  
  25. Disconnect the Mass Air Flow (MAF) connector.
  26.  
  27. Disconnect the Evaporative Emissions (EVAP) purge regulator and valve.
  28.  
  29. Rotate the secondary air injection pump duct 45° clockwise and remove from the air cleaner housing.
  30.  
  31. Unbolt the air cleaner assembly and remove.
  32.  
  33. Remove the Camshaft Position (CMP) sensor housing and shutter wheel.
  34.  
  35. Remove the cylinder head covers.
  36.  
  37. Install the camshaft locator bar tool No. 3391 or equivalent onto the camshaft locking plates.
  38.  
  39. Loosen the camshaft bolts and back out 5 revolutions.
  40.  
  41. Remove the camshaft locator bar and remove camshaft gears using tool No. T40001, or equivalent.
  42.  
  43. Carefully lift out the oil supply lines for the camshaft bearings. Use care to not damage the positioning clips.
  44.  
  45. Secure the camshaft adjuster using the bracket tensioner tool No. 3366 or equivalent. Use care to not over-tighten the bracket adjuster as the camshaft adjuster could be damaged.
  46.  
  47. Verify that both camshafts are at Top Dead Center (TDC). The notch on the camshaft behind the cam sprocket should align with the arrows on the camshaft bearing caps.
  48.  
  49. Make sure the camshafts are at TDC.
  50.  
  51. Clean the camshaft sprockets and cam drive chain and make alignment marks on the sprocket and chain in alignment with the top dead center marks.
  52.  
  53. Remove the camshaft adjuster retaining bolts, leaving the adjuster in place.
  54.  
  55. Remove the camshaft journals numbers 1, 3, and 5 from both cams and journal number 7 from the exhaust camshaft.
  56.  
  57. Working in a diagonal sequence, carefully loosen and remove the cam journal caps numbers 2 and 4.
  58.  
  59. Remove both camshafts together with the camshaft adjuster assembly.
  60.  



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Fig. The camshaft sprockets are held using tool No. 3391 or equivalent-2.8L V6 engines



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Fig. The camshaft gears are removed using tool No. T40001 or equivalent-2.8L V6 engines



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Fig. The notches in the camshaft align with the arrows on the cam journal caps when the camshafts are at Top Dead Center (TDC)-2.8L V6 DOHC engine



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Fig. Replace the rubber/metal gasket for the camshaft adjuster assembly, and apply a thin layer of sealant on the hatched surface as illustrated



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Fig. The camshaft drive chain is installed on the camshaft sprockets 16 drive chain rollers apart-1.8L and 2.8L V6 DOHC engines



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Fig. Apply sealant to the shaded areas for camshaft bearing caps numbers 1 and 7-2.8L V6 DOHC Engines



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Fig. Apply a thin bead of sealant at the corners of the outer camshaft journals-2.8L V6 DOHC engines



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Fig. Camshaft belt routing-2.8L V6 DOHC engines

To install:

  1. Install a new the rubber/metal gasket for the camshaft tensioner assembly, and apply a thin layer of sealant on the top of the gasket between the straight part of the inside edge and the two fastener holes.
  2.  
  3. Install the drive chain on the camshaft sprockets and align the marks made during disassembly.
  4.  
  5. If a new chain is installed or the marks are no longer visible, install the chain on the camshaft sprockets such that the distance between the two camshaft sprockets is 16 drive chain rollers.
  6.  
  7. Use an assistant to place the camshaft adjuster between the camshaft drive chain and install the camshafts and adjuster into the cylinder head.
  8.  
  9. Apply a film of oil to all the camshaft journal surfaces.
  10.  
  11. Tighten the camshaft adjuster to 88 inch lbs. (10 Nm).
  12.  
  13. Use an alternating diagonal pattern and install the camshaft journals numbers 2 and 4 on both camshafts and torque to 88 inch lbs. (10 Nm).
  14.  
  15. Make sure both camshafts align with the TDC marks.
  16.  


NOTE
The notch of the exhaust camshaft is slightly offset inward from the drive chain roller.

  1. Apply sealant to the double camshaft bearing cap (No. 1) and the outer bearing cap (No. 7) at their mating surfaces. Refer to the shaded area in the illustration.
  2.  
  3. Install the remaining camshaft bearing caps and torque to 88 inch lbs. (10 Nm).
  4.  
  5. Install the camshaft bearing oil lines.
  6.  
  7. Remove the cam chain bracket tensioner tool No. 3366 or equivalent.
  8.  
  9. Apply sealant to the corners of the camshaft journal caps and the gasket surface for the head covers.
  10.  
  11. Replace the camshaft oil seal and install the camshaft cam belt sprocket and torque the sprocket bolt to 41 ft. lbs. (55 Nm).
  12.  
  13. Install the cylinder head covers and torque the fasteners to 88 inch lbs. (10 Nm).
  14.  
  15. Install the camshaft toothed belt.
  16.  
  17. Install the accessory drive belt.
  18.  
  19. Install the remaining equipment in the reverse order of removal.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  24.  
  25. Check the oil level before starting the engine
  26.  
  27. Set the clock to the correct time.
  28.  
  29. Enter the radio security code.
  30.  


NOTE
Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  
  3. Adjust the headlights if necessary.
  4.  

Inspection
Camshaft

Degrease the camshaft using a safe solvent. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable or a bearing journal scored, the camshaft should be replaced. Check the lobes and journals with a micrometer. Measure the lobes from nose to heel. If all intake or all exhaust lobes Do NOT measure the same, replace the camshaft. If the lobes and journals appear intact, place the front and rear journals in V-blocks. Position a dial indicator on the center journal and rotate the camshaft. If deviation exceeds 0.0004 inch (0.01mm) replace the camshaft.

Hydraulic Lifters

The hydraulic lifters are installed into a machined bore in the cylinder head and receive their lubrication via a series of oil galleys machined into to the engine block and cylinder head. The engine oil is supplied under pressure by the engine's oil pump.

If removed the observe the following guidelines:



Store the lifter with the camshaft contact surface facing down
 
The lifter must be reinstalled in the same location that it was removed from
 
The hydraulic lifters are not serviceable. If defective they must be replaced
 

If a valve has contacted a piston, the lifter associated with that valve should be checked for an out of round condition. If the lifter is dished or out of round by more than 0.002 inches (0.05mm), or if the lifter binds in the bore of the cylinder head, it should be replaced.

To inspect a hydraulic lifter for excessive noise proceed as follows:

  1. Start the engine and allow the engine to run until the coolant temperature reaches 176°F (80°C).
  2.  
  3. Raise the engine speed to 2,500 RPM for 2 minutes, and if necessary test drive the vehicle.
  4.  
  5. If the valve noises disappears but then reoccurs during the test drive, on 1.8L and 2.8L V6 models, the oil retaining valve should be replaced.
  6.  

The oil retaining valve is located as follows:



1.8L engines: Oil filter housing
 
2.8L V6 engines: Under cover plate at top of engine under intake manifold
 

  1. If the valve lifter(s) is/are still noisy proceed as follows:
  2.  
    1. Remove the cam cover(s).
    2.  
    3. Position the valve such that the pointed end is facing upward.
    4.  
    5. Using a soft wooded or plastic wedge, press down on the lifter.
    6.  
    7. On 1.8L and 2.8L V6 models if a 0.008 inch (0.20mm) feeler gauge can be inserted between the camshaft lobe and lifter, the valve lifter should be replaced.
    8.  
    9. On 2.0L and 2.8L VR6 models, if a 0.004 inch (0.10mm) feeler gauge can be inserted between the camshaft lobe and lifter, the valve lifter should be replaced.
    10.  

  3. Remove the camshaft(s) to replace the hydraulic lifter(s).
  4.  



Click image to see an enlarged view

Fig. The hydraulic lifter's oil flow is controlled by the engine oil check valves. The 2.8L V6 valves shown are located in the engine block just below the intake manifold

 
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