Volkswagen Cars 2000-05

Camshaft, Bearings & Lifters 2

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Removal & Installation



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.  

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.  

4.0L (Bdp) Engine


On both cylinder heads, remove or disconnect:
  1. Valve cover.
  2.  
  3. Intake manifold.
  4.  
  5. Timing chain.
  6.  
  7. Control housing from cylinder head.
  8.  

 

  1. On both cylinder heads, remove or disconnect:

    Valve cover.
     
    Intake manifold.
     
    Timing chain.
     
    Control housing from cylinder head.
     

  2.  

Cylinder Bank No. 1

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



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

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

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

 
Remove the camshaft and lift out the valve lifters.
 

  1. On the intake camshaft, install the bearing caps in sequence as follows:
    1. Bearing caps 3 and 7 diagonally: Torque to 44 inch lbs. (5 Nm) plus 45°.
    2.  
    3. Bearing cap 5: Torque to 44 inch lbs. (5 Nm) plus 45°.
    4.  
    5. Bearing caps 1 and 9: Torque to 44 inch lbs. (5 Nm) plus 45°.
    6.  

  2.  
  3. On the exhaust camshaft, install the bearing caps in sequence as follows:

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

  4.  
  5. Adjust the camshafts in cylinder head to TDC on cylinder no. 1.
  6.  
  7. Lightly oil the sealing ring contact surfaces of camshaft before installing control housing.
  8.  
  9. Lightly oil camshafts and slowly slide control housing over camshaft sealing rings.
  10.  
  11. Install control housing to cylinder head and tighten to 72 inch lbs. (8 Nm).
  12.  
  13. Install the timing chain and adjust the valve timing.
  14.  
  15. To complete installation, reverse the removal procedure.
  16.  


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

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

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

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

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

  6.  
  7. Remove the camshaft and lift out the valve lifters.
  8.  

  1. On the intake camshaft, install the bearing caps in sequence as follows:

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

  2.  
  3. On the exhaust camshaft, install the bearing caps in sequence as follows:

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

  4.  
  5. Adjust the camshafts in cylinder head to TDC on cylinder no. 1.
  6.  
  7. Lightly oil the sealing ring contact surfaces of camshaft before installing control housing.
  8.  
  9. Lightly oil camshafts and slowly slide control housing over camshaft sealing rings.
  10.  
  11. Install control housing to cylinder head and tighten to 72 inch lbs. (8 Nm).
  12.  
  13. Install the timing chain and adjust the valve timing.
  14.  
  15. To complete installation, reverse the removal procedure.
  16.  

Cylinder Bank No. 2

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



Remove camshafts as follows:
 
On the intake camshaft, remove the bearing caps as follows:
  1. Bearing caps 21 and 29.
  2.  
  3. Bearing cap 25.
  4.  
  5. Bearing caps 23 and 27 alternating in a diagonal sequence.
  6.  

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

Bearing caps 22 and 30.
 
Bearing cap 26.
 
Bearing caps 24 and 28 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 cylinder bank 1-4.0L engine



Click image to see an enlarged view

Fig. Camshaft bearing cap identification cylinder bank 2-4.0L engine


To install:



On both cylinder heads, 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 23 and 27 diagonally: Torque to 44 inch lbs. (5 Nm) plus 45°.
  2.  
  3. Bearing cap 25: Torque to 44 inch lbs. (5 Nm) plus 45°.
  4.  
  5. Bearing caps 21 and 29: Torque to 44 inch lbs. (5 Nm) plus 45°.
  6.  

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

Bearing caps 24 and 28 diagonally: Torque to 44 inch lbs. (5 Nm) plus 45°.
 
Bearing cap 26: Torque to 44 inch lbs. (5 Nm) plus 45°.
 
Bearing caps 22 and 20: Torque to 44 inch lbs. (5 Nm) plus 45°.
 

 
Adjust the camshafts in cylinder heads 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.
 


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

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

    Bearing caps 21 and 29.
     
    Bearing cap 25.
     
    Bearing caps 23 and 27 alternating in a diagonal sequence.
     

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

    Bearing caps 22 and 30.
     
    Bearing cap 26.
     
    Bearing caps 24 and 28 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 cylinder bank 1-4.0L engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification cylinder bank 2-4.0L engine

  8.  

To install:

  1. On both cylinder heads, 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.  

  1. On the intake camshaft, install the bearing caps in sequence as follows:

    Bearing caps 23 and 27 diagonally: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing cap 25: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing caps 21 and 29: Torque to 44 inch lbs. (5 Nm) plus 45°.
     

  2.  
  3. On the exhaust camshaft, install the bearing caps in sequence as follows:

    Bearing caps 24 and 28 diagonally: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing cap 26: Torque to 44 inch lbs. (5 Nm) plus 45°.
     
    Bearing caps 22 and 20: Torque to 44 inch lbs. (5 Nm) plus 45°.
     

  4.  
  5. Adjust the camshafts in cylinder heads to TDC on cylinder no. 1.
  6.  
  7. Lightly oil the sealing ring contact surfaces of camshaft before installing control housing.
  8.  
  9. Lightly oil camshafts and slowly slide control housing over camshaft sealing rings.
  10.  
  11. Install control housing to cylinder head and tighten to 72 inch lbs. (8 Nm).
  12.  
  13. Install the timing chain and adjust the valve timing.
  14.  
  15. To complete installation, reverse the removal procedure.
  16.  

8 Valve Engine


Click image to see an enlarged view

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

  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.  

To install:



Click image to see an enlarged view

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

  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.  

Alh Engine
  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.
  2.  


NOTE
When installing the camshaft the camshaft lobes for cylinder no.1 must point upward.

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

Except Alh Engine
  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 least12
  6.  

 
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