Volkswagen Cars 2000-05

Camshaft, Bearings & Lifters 1

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Description



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 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.

Inspection



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 0.01mm (0.0004 inches) replace the camshaft.

Inspect the camshaft and lifters/followers as described earlier in this section.

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.

Removal & Installation




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

1.8L Engine


Click image to see an enlarged view

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

  1. Place the lock carrier into the service position as follows:
    1. Remove or disconnect:
    2.  



    Front bumper.
     
    Any wiring or connector that would inhibit locking the carrier.
     
    3 quick-release screws on the front noise insulation panel.
     
    Air guide between the lock carrier and the air filter.
     
    If installed, retaining clamps for the wiring harness at the left side of the radiator frame.
     
    No. 2 bolts and install Support 3369 or equivalent.
     
    Remaining bolts and pull the lock carrier out to the stop.
     
    To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
     

  2.  
  3. Remove or disconnect:
    1. Negative battery cable.
    2.  
    3. Accessory drive belts.
    4.  
    5. Engine covers.
    6.  
    7. Timing belt upper cover.
    8.  

  4.  
  5. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at TDC.
  6.  
  7. Using a T45 Torx® wrench, loosen the timing belt tensioner.
  8.  
  9. Push down on the tensioner, and remove the belt from the camshaft gear.
  10.  
  11. Remove or disconnect:

    Torx® bolt and swing the tensioner assembly bracket forward.
     
    Valve cover.
     

  12.  
  13. Using Retainer 3036 or equivalent, loosen the cam gear retaining bolt.
  14.  
  15. Remove:

    Camshaft gear.
     
    Housing for CMP sensor and shutter wheel.
     

  16.  
  17. Secure the hydraulic chain tensioner with Bracket-Tensioner 3366 or equivalent.
  18.  
  19. Verify that the camshafts are at TDC for the No. 1 cylinder. Both camshaft markings must align with arrows on the bearing caps.
  20.  
  21. Clean the drive chain and the cam chain gears opposite both arrows on the bearing caps. Matchmark the installed position using paint.
  22.  


    Click image to see an enlarged view

    Fig. Over-tightening will damage the chain tensioner (3366)-1.8L engine



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.



Click image to see an enlarged view

Fig. To ensure proper installation, matchmark the chain-to-camshaft position-1.8L engine



Click image to see an enlarged view

Fig. Camshaft bearing cap identification-1.8L engine



Remove or disconnect:
  1. Bearing caps 3 and 5 from the intake and exhaust camshafts.
  2.  
  3. Double bearing cap.
  4.  
  5. Both bearing caps from the chain gears on the intake and exhaust camshafts.
  6.  
  7. Hydraulic chain tensioner retaining bolts.
  8.  

 
In an alternating and diagonal sequence, loosen the bearing caps 2 and 4 of the intake and exhaust manifold, then remove.
 
Remove the camshafts with the hydraulic chain tensioner.
 

To install:


WARNING
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.



Click image to see an enlarged view

Fig. To ensure a proper seal, be sure to apply sealant to the hatched area-1.8L engine



Replace the rubber/metal chain tensioner gasket and apply sealant to the hatched area, as shown.
 
Install the drive chain on the camshaft as follows:
  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 notchesAB
  4.  

 
Slide the hydraulic chain tensioner between the drive chain.
 
Install the camshafts with the chain tensioner into the cylinder head.
 
Oil the camshaft contact surfaces.
 


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 3366.
  8.  
  9. Lightly coat the cylinder head mating surface of the double bearing cap with sealant, then install.
  10.  
  11. Install:
    1. Remaining bearing caps: 84 inch lbs. (10 Nm).
    2.  
    3. Camshaft gear. Retaining bolt: 48 ft. lbs. (65 Nm).
    4.  
    5. CMP shutter wheel and housing cover.
    6.  
    7. Valve cover.
    8.  

  12.  
  13. Align the camshaft gear and the vibration damper with the TDC markings.
  14.  
  15. Install or connect:

    Timing belt.
     
    Accessory drive belts, then the engine cover.
     
    Lock carrier.
     
    Negative battery cable.
     

  16.  

  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.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. Camshaft bearing cap identification-1.8L Engine



Click image to see an enlarged view

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.  

  1. Place the lock carrier into the service position as follows:
    1. Remove or disconnect:

      Front bumper.
       
      Any wiring or connector that would inhibit locking the carrier.
       
      3 quick-release screws on the front noise insulation panel.
       
      Air guide between the lock carrier and the air filter.
       
      If installed, retaining clamps for the wiring harness at the left side of the radiator frame.
       
      No. 2 bolts and install Support 3369 or equivalent.
       
      Remaining bolts and pull the lock carrier out to the stop.
       

    2.  
    3. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    4.  

  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Accessory drive belts.
     
    Engine covers.
     
    Timing belt upper cover.
     

  4.  
  5. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at TDC.
  6.  
  7. Using a T45 Torx® wrench, loosen the timing belt tensioner.
  8.  
  9. Push down on the tensioner, and remove the belt from the camshaft gear.
  10.  
  11. Remove or disconnect:

    Torx® bolt and swing the tensioner assembly bracket forward.
     
    Valve cover.
     

  12.  
  13. Using Retainer 3036 or equivalent, loosen the cam gear retaining bolt.
  14.  
  15. Remove:

    Camshaft gear.
     
    Housing for CMP sensor and shutter wheel.
     

  16.  
  17. Secure the hydraulic chain tensioner with Bracket-Tensioner 3366 or equivalent.

    Click image to see an enlarged view

    Fig. Over-tightening will damage the chain tensioner (3366)-1.8L engine

  18.  
  19. Verify that the camshafts are at TDC for the No. 1 cylinder. Both camshaft markings must align with arrows on the bearing caps.
  20.  
  21. Clean the drive chain and the cam chain gears opposite both arrows on the bearing caps. Matchmark the installed position using paint.
    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.



    Click image to see an enlarged view

    Fig. To ensure proper installation, matchmark the chain-to-camshaft position-1.8L engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-1.8L engine

  22.  
  23. Remove or disconnect:

    Bearing caps 3 and 5 from the intake and exhaust camshafts.
     
    Double bearing cap.
     
    Both bearing caps from the chain gears on the intake and exhaust camshafts.
     
    Hydraulic chain tensioner retaining bolts.
     

  24.  
  25. In an alternating and diagonal sequence, loosen the bearing caps 2 and 4 of the intake and exhaust manifold, then remove.
  26.  
  27. Remove the camshafts with the hydraulic chain tensioner.

    Click image to see an enlarged view

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

  28.  

To install:


WARNING
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.



Click image to see an enlarged view

Fig. To ensure a proper seal, be sure to apply sealant to the hatched area-1.8L engine

  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:
    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.  

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

  10.  
  11. Tighten the bearing caps 2 and 4 of the intake and exhaust camshafts in an alternating diagonal sequence to 84 inch lbs. (10 Nm).
  12.  
  13. Install both bearing caps on the chain sprockets of the intake and exhaust camshafts and tighten to 84 inch lbs. (10 Nm).
  14.  
  15. Verify the correct positions of the camshafts.
  16.  
  17. Remove the Bracket-Tensioner 3366.
  18.  
  19. Lightly coat the cylinder head mating surface of the double bearing cap with sealant, then install.
  20.  
  21. Install:

    Remaining bearing caps: 84 inch lbs. (10 Nm).
     
    Camshaft gear. Retaining bolt: 48 ft. lbs. (65 Nm).
     
    CMP shutter wheel and housing cover.
     
    Valve cover.
     

  22.  
  23. Align the camshaft gear and the vibration damper with the TDC markings.
  24.  
  25. Install or connect:

    Timing belt.
     
    Accessory drive belts, then the engine cover.
     
    Lock carrier.
     
    Negative battery cable.
     

  26.  

1.9L Diesel Engines
Ahh Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Timing belt cover(s), the timing belt, cylinder head cover and the camshaft sprocket.
     

  4.  
  5. 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.
  6.  
  7. Remove:

    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.
     
    Bearing caps and the camshaft.
     

  8.  

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. Cap nuts, diagonally and in several steps: 15 ft. lbs. (20 Nm). Do not over tighten. Camshaft shaft end-play should be about 0.006 in. (0.15mm).
  4.  
  5. Install the drive sprocket and timing belt. Wait at least 1 / 2 hour after installing the camshaft before starting the engine to allow the lifters to leak down.
  6.  

Alh/Bew/Brm Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Fuel lines from fuel filter
     
    Right headlight
     
    Connecting line between charge air cooler and intake manifold
     
    Upper timing belt cover
     
    Valve cover
     
    Brake booster vacuum pump
     
    Timing belt from camshaft sprocket
     
    Rotate crankshaft counterclockwise slightly
     
    Loosen camshaft sprocket bolt one turn
     
    Use 2 jaw puller T40001 and press camshaft sprocket off
     

  4.  
  5. Remove bearing caps no. 1, 3 and 5.
  6.  
  7. Loosen bearing caps no. 2 and 4 in steps and diagonally.
  8.  

To install:

  1. Ensure the pistons are not at TDC.
    NOTE
    When installing the camshaft the camshaft lobes for cylinder no.1 must point upward.

  2.  
  3. Lubricate the bearing camshaft surface with oil.
  4.  
  5. Install the camshaft.
  6.  
  7. Tighten bearing caps no. 2 and 4 alternately and diagonally to 15 ft. (20 Nm).
  8.  
  9. Lightly coat the contact face of bearing cap no. 1 with sealant.
  10.  
  11. Tighten bearing caps no. 1, 3 and 5 alternately and diagonally to 15 ft. (20 Nm).
  12.  
  13. Lightly tap bearing cap no. 5 to fit the camshaft.
  14.  
  15. The remainder of the installation is the reverse of the removal procedure.
  16.  

16-Valve Engines
  1. Remove the timing belt cover.
  2.  
  3. Remove the upper intake manifold and cylinder head cover.
  4.  
  5. Turn the engine to TDC on cylinder No. 1, then slacken and remove the timing belt and camshaft sprocket.
  6.  
  7. With a felt marker only, matchmark the timing chain to the camshafts for reinstallation.
  8.  
  9. Remove the camshaft chain.
  10.  
  11. On the intake camshaft, remove bearing caps No. 5 and 7 and the chain end cap. Then loosen bearing caps No. 6 and 8 alternately and diagonally.
  12.  
  13. On the exhaust camshaft, remove bearing caps No. 1 and 3 and the end caps. Then loosen bearing caps No. 2 and 4 alternately and diagonally.
  14.  
  15. Remove the remaining bearing cap bolts and remove the camshafts.
  16.  

To install:

  1. Lubricate the camshaft bearing journals and lobes 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 No. 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 No. 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 end play 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 DOHC Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove camshaft adjuster.
  4.  
  5. Remove timing belt.
  6.  
  7. Loosen camshaft gear, to do so use retainer 3036.
  8.  
  9. Pull off camshaft gear using puller T40001 , claw T40001/6 and claw T40001/7.
  10.  
  11. Remove timing belt cover at rear of cylinder head.
  12.  
  13. Remove guide frame bolts evenly from outside toward inside and remove guide frame.
  14.  
  15. Carefully remove camshaft upward and place on a clean surface.
  16.  
  17. Remove old sealant from guide frame groove as well as from sealing surfaces.
  18.  
  19. Prevent dirt and adhesive residue from entering cylinder head.
  20.  

To install:


NOTE
Sealing surfaces must be completely free of oil and grease. Pistons must not be at Top Dead Center (TDC). Make sure that all roller cam followers properly rest on valve shaft tips. Oil journal surfaces of camshafts.

  1. Carefully insert camshafts into camshaft bearings of cylinder head. Cams of cylinder 4 must face each other. Recesses must point to each other.

    Click image to see an enlarged view

    Fig. Cams of cylinder 4 must face each other and recesses must point to each other-2.0L DOHC engine

  2.  
  3. Apply an even, slightly raised bead of sealant D 188 800 A1 into clean grooves of guide frame. Apply sealant uniformly on sealing surface. Note expiration date for sealant. Sealant must not be applied too thick. Wipe off excess sealant if necessary using a lint-free cloth.
    NOTE
    Attaching and bolting the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces.

  4.  
  5. Place guide frame onto cylinder head.
  6.  
  7. Gently tighten new bolts from inside working toward outside in several stages.
  8.  
  9. Tighten bolts in sequence to 71 inch lbs. (8 Nm).

    Click image to see an enlarged view

    Fig. Tighten bolts in sequence shown-2.0L DOHC engine

  10.  
  11. Drive in cap using pressure piece 3334 approx. 0.04-0.08 inch (1-2mm).
  12.  
  13. Install camshaft seal.
  14.  
  15. Install rear timing belt cover.
  16.  
  17. Insert fitting key into camshaft.
  18.  
  19. Install camshaft gear. To tighten bolt, hold camshaft gear using retainer 3036 . Tightening torque 45 ft. lbs. (65 Nm).
  20.  
  21. When turning camshaft, pistons may not be at TDC for any cylinder. Valves and/or pistons may be damaged.
  22.  
  23. Be sure fitting key is properly seated.
  24.  
  25. Install timing belt .
  26.  
  27. Install camshaft adjuster .
  28.  
  29. Install cylinder head cover.
  30.  
  31. The rest of installation is in reverse order of removal.
  32.  

2.0L Engine


Before servicing the vehicle, refer to the Precautions section.
 
Remove or disconnect:
  1. Negative battery cable.
  2.  
  3. Timing belt cover(s), the timing belt
  4.  
  5. Camshaft sprocket and cylinder head cover.
  6.  

 
Number the bearing caps from front-to-back. 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.
 
Remove or disconnect:

Front and rear bearing caps. Loosen the remaining bearing cap nuts diagonally, in several steps, starting from the outside caps near the ends of the head and working toward the center.
 
Bearing caps and the camshaft.
 
If required, lifters from the valves. Keep them in order so they can be installed in their original positions. Place them in a bath of oil or place them upside down to prevent air from entering them.
 

 

To install:



Install or connect:
  1. 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. 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 tightened to 15 ft. lbs. (20 Nm). Do not over-tighten.
  4.  
  5. Drive sprocket. Bolt: 58 ft. lbs. (80 Nm).
  6.  

 
Align the timing marks, install the timing belt and adjust the tension.
 
On engines with hydraulic lifters, wait at least12

Camshaft shaft end-play: 0.006 in. (0.15mm)
 
Bearing cap bolts: 15 ft. lbs. (20 Nm)
 
Camshaft sprocket bolt: 58 ft. lbs. (80 Nm)
 

 


Click image to see an enlarged view

Fig. Exploded view of the camshaft and related components-2.0L engines


2.0L SOHC Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Timing belt cover(s), the timing belt
     
    Camshaft sprocket and cylinder head cover.
     

  4.  
  5. Number the bearing caps from front-to-back. 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.
  6.  
  7. Remove or disconnect:

    Front and rear bearing caps. Loosen the remaining bearing cap nuts diagonally, in several steps, starting from the outside caps near the ends of the head and working toward the center.
     
    Bearing caps and the camshaft.
     
    If required, lifters from the valves. Keep them in order so they can be installed in their original positions. Place them in a bath of oil or place them upside down to prevent air from entering them.
     

  8.  

To install:

  1. Install or connect:

    New oil seal and end-plug in the cylinder head. Lubricate the camshaft bearing journals and lobes and set the camshaft in place.
     
    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 tightened to 15 ft. lbs. (20 Nm). Do not over-tighten.
     
    Drive sprocket. Bolt: 58 ft. lbs. (80 Nm).
     

  2.  
  3. Align the timing marks, install the timing belt and adjust the tension.
  4.  
  5. On engines with hydraulic lifters, wait at least 1 / 2 hour after installing the camshaft before starting the engine to allow the lifters to leak down. Observe the following values:

    Camshaft shaft end-play: 0.006 in. (0.15mm)
     
    Bearing cap bolts: 15 ft. lbs. (20 Nm)
     
    Camshaft sprocket bolt: 58 ft. lbs. (80 Nm)

    Click image to see an enlarged view

    Fig. Exploded view of the camshaft and related components-2.0L engines

     

  6.  

2.8L (AAA) Engine

This procedure requires special tool 3268 or equivalent. This is a setting tool that holds the camshafts in the correct position for installing the timing chains.



Before servicing the vehicle, refer to the Precautions section.
 
Remove or disconnect:
  1. Distributor cap, wires and wire guide as an assembly.
  2.  
  3. Upper intake manifold.
  4.  
  5. Cylinder head cover.
  6.  
  7. Timing chain tensioner bolt and the upper timing chain cover.
  8.  

 
Rotate the crankshaft to TDC of No. 1 piston.
 
Mark the direction of travel on the upper camshaft drive chain. Remove the tensioner shoe and the chain.
 
Hold the camshafts at the flats with a 24mm wrench and remove the bolts to remove the sprockets. Note the position of the distributor drive on the short camshaft.
 


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.



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.
 
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.
 


Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. The camshaft setting tool holds the camshafts in place when installing the chain-do not use this tool to loosen or tighten the sprocket bolts


To install:

  1. Lubricate the long camshaft and the cylinder head bearing surfaces and set the camshaft in place. Install bearing caps 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. Nuts: 15 ft. lbs. (20 Nm).
  4.  
  5. Repeat the process with the short camshaft, using bearing caps 2 and 6 to draw the camshaft down against the springs.
  6.  
  7. Hold the camshaft with a 24mm wrench and install the sprockets. Be sure the distributor drive is correctly positioned. Bolts: 74 ft. lbs. (100 Nm).
  8.  
  9. Be sure the crankshaft is at TDC on No. 1 piston. Install the setting tool and install the timing chain.
  10.  
  11. Install the tensioner shoe and temporarily install the upper timing chain cover. Install the tensioner bolt and remove the setting tool. Rotate the crankshaft 4 full turns and stop at TDC of No. 1 piston. The setting tool should fit into the camshafts.
  12.  
  13. Remove the tensioner bolt and upper timing chain cover again. Clean the old sealant off the cylinder head gasket and apply new sealant.
  14.  
  15. Install:
    1. Upper timing chain cover. Bolts: 82 inch lbs. (10 Nm).
    2.  
    3. Tensioner bolt and tighten to 15 ft. lbs. (20 Nm).
    4.  
    5. Cylinder head cover, upper intake manifold and ignition system components.
    6.  

  16.  

2.8L (AHA/ATQ) Engine


Remove or disconnect:
  1. Timing belt.
  2.  
  3. Valve cover(s).
  4.  
  5. On the left cylinder head, Camshaft Position (CMP) sensor.
  6.  
  7. On the right cylinder head, plug/cover on the head.
  8.  
  9. Camshaft timing belt sprocket.
  10.  

 


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



Camshaft bearing caps 2 and 3.
 



Gradually and evenly, loosen the nuts for the camshaft bearing caps 1 and 4, in a diagonal sequence.
 
Remove the camshaft and lift out the valve lifters. If it is to be reused, it must go in the bore from which it was removed.
 


Click image to see an enlarged view

Fig. Camshaft bearing cap identification-2.8L (AHA) engine


To install:

  1. Install or connect:
    1. Lifters into their respective bore.
    2.  
    3. Bearing caps 1 and 4 in a alternating and diagonal sequence.
    4.  
    5. Bearing caps 2 and 3. All bearing caps: 15 ft. lbs. (20 Nm).
    6.  

  2.  


WARNING
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.



Camshaft timing belt sprocket. Mounting bolt: 52 ft. lbs. (71 Nm).
 
On the right cylinder head, plug/cover on the head.
 
On the left cylinder head, CMP sensor. Mounting bolts: 89 inch lbs. (10 Nm).
 
Valve cover.
 
Timing belt.
 

2.8L (Atq) Engine
  1. Remove or disconnect:
    NOTE
    DO NOT allow the bearing caps to become mixed up.



    Timing belt.
     
    Valve cover(s).
     
    On the left cylinder head, Camshaft Position (CMP) sensor.
     
    On the right cylinder head, plug/cover on the head.
     
    Camshaft timing belt sprocket.
     



    Camshaft bearing caps 2 and 3.
     

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

    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-2.8L (ATQ) engine

  6.  

To install:

  1. Install or connect:
    WARNING
    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.



    Lifters into their respective bore.
     
    Bearing caps 1 and 4 in a alternating and diagonal sequence.
     
    Bearing caps 2 and 3. All bearing caps: 15 ft. lbs. (20 Nm).
     



    Camshaft timing belt sprocket. Mounting bolt: 52 ft. lbs. (71 Nm).
     
    On the right cylinder head, plug/cover on the head.
     
    On the left cylinder head, CMP sensor. Mounting bolts: 89 inch lbs. (10 Nm).
     
    Valve cover.
     
    Timing belt.
     

  2.  

2.8L (Bdf) Engine
  1. Remove or disconnect:
    NOTE
    DO NOT allow the bearing caps to become mixed up.



    Valve cover.
     
    Intake manifold.
     
    Timing chain.
     
    Four bolts and control housing from cylinder head.
     

  2.  
  3. On the intake camshaft, remove the bearing caps as follows:

    Bearing caps 1 and 13.
     
    Bearing caps 3 and 11.
     
    Bearing cap 7.
     
    Bearing caps 5 and 9 alternating in a diagonal sequence.
     

  4.  
  5. On the exhaust camshaft, remove the bearing caps as follows:

    Bearing caps 2 and 14.
     
    Bearing cap 4 and 12.
     
    Bearing cap 8.
     
    Bearing caps 6 and 10 alternating in a diagonal sequence.
     

  6.  
  7. Remove the camshaft and lift out the valve lifters.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-2.8L engine (BDF)

  8.  

To install:

  1. Install or connect:


  2.  
  3. Install the lifters into their respective bore.
  4.  
  5. Ensure cam lobes for cylinder no 1 are pointing upward and that the pistons are not at TDC.
  6.  
  7. Oil the camshaft journal surfaces.
  8.  
  9. Insert the respective camshafts into their mountings.
  10.  
  11. On the intake camshaft, install the bearing caps in sequence as follows:

    Bearing caps 5 and 9: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing caps 1 and 13: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing cap 7: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing caps 3 and 11: Torque to 44 inch lbs. (5 Nm) plus 45°.
     

  12.  
  13. On the exhaust camshaft, install the bearing caps in sequence as follows:

    Bearing caps 6 and 10: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing caps 2 and 14: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing cap 8: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing caps 4 and 12: Torque to 44 inch lbs. (5 Nm) plus 45°.
     

  14.  
  15. Adjust the camshafts in cylinder head to TDC on cylinder no. 1.
  16.  
  17. Lightly oil the sealing ring contact surfaces of camshaft before installing control housing.
  18.  
  19. Lightly oil camshafts and slowly slide control housing over camshaft sealing rings.
  20.  
  21. Install control housing to cylinder head and tighten to 72 inch lbs. (8 Nm).
  22.  
  23. Install the timing chain and adjust the valve timing.
  24.  
  25. To complete installation, reverse the removal procedure.
  26.  

2.8L (BDF) Engine


Remove or disconnect:
  1. Valve cover.
  2.  
  3. Intake manifold.
  4.  
  5. Timing chain.
  6.  
  7. Four bolts and control housing from cylinder head.
  8.  

 


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



On the intake camshaft, remove the bearing caps as follows:
  1. Bearing caps 1 and 13.
  2.  
  3. Bearing caps 3 and 11.
  4.  
  5. Bearing cap 7.
  6.  
  7. Bearing caps 5 and 9 alternating in a diagonal sequence.
  8.  

 
On the exhaust camshaft, remove the bearing caps as follows:

Bearing caps 2 and 14.
 
Bearing cap 4 and 12.
 
Bearing cap 8.
 
Bearing caps 6 and 10 alternating in a diagonal sequence.
 

 
Remove the camshaft and lift out the valve lifters.
 


Click image to see an enlarged view

Fig. Camshaft bearing cap identification-2.8L engine (BDF)


To install:



Install or connect:
 
Install the lifters into their respective bore.
 
Ensure cam lobes for cylinder no 1 are pointing upward and that the pistons are not at TDC.
 
Oil the camshaft journal surfaces.
 
Insert the respective camshafts into their mountings.
 
On the intake camshaft, install the bearing caps in sequence as follows:
  1. Bearing caps 5 and 9: Torque to 44 inch lbs. (5 Nm) plus 45°.
  2.  
  3. Bearing caps 1 and 13: Torque to 44 inch lbs. (5 Nm) plus 45°.
  4.  
  5. Bearing cap 7: Torque to 44 inch lbs. (5 Nm) plus 45°.
  6.  
  7. Bearing caps 3 and 11: Torque to 44 inch lbs. (5 Nm) plus 45°.
  8.  

 
On the exhaust camshaft, install the bearing caps in sequence as follows:

Bearing caps 6 and 10: Torque to 44 inch lbs. (5 Nm) plus 45°.
 
Bearing caps 2 and 14: Torque to 44 inch lbs. (5 Nm) plus 45°.
 
Bearing cap 8: Torque to 44 inch lbs. (5 Nm) plus 45°.
 
Bearing caps 4 and 12: Torque to 44 inch lbs. (5 Nm) plus 45°.
 

 
Adjust the camshafts in cylinder head to TDC on cylinder no. 1.
 
Lightly oil the sealing ring contact surfaces of camshaft before installing control housing.
 
Lightly oil camshafts and slowly slide control housing over camshaft sealing rings.
 
Install control housing to cylinder head and tighten to 72 inch lbs. (8 Nm).
 
Install the timing chain and adjust the valve timing.
 
To complete installation, reverse the removal procedure.
 

 
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