1.4 TSI engine (EA111) · Cylinder head, valve gear · Cylinder head

Removing and installing camshaft housing

Special tools and workshop equipment required

  • Dial gauge - VAS 6079-
  • Puller - T10094 A-
  • Dial gauge adapter - T10170- or dial gauge adapter - T10170 A-
  • Camshaft clamp - T10171 A-
  • Counter-hold tool - T10172-
  • Adapter - T10172/1-
  • Pin - T40011-
  • Spark plug socket - 3122 B-
  • Torque wrench - V.A.G 1331-
  • Sealant - D 154 103 A1-

1.2.1 Removing

  • Remove valve timing housing (Passat, Passat CC)
  • Turn crankshaft to TDC for No. 1 cylinder. Then turn crankshaft 45° in engine direction and remove camshaft timing sprockets with timing chain ⇒ 4.2 Adjusting valve timing.
  • Unbolt camshaft sealing covers.
  • Pull connectors off fuel pressure sender for low-pressure - G410- and off high-pressure pump.
  • Unscrew earth cable from camshaft housing.
  • Remove ignition coils. Use puller -T10094 A- for this purpose ⇒ 1.2 Removing and installing ignition coils with output stage.
  • Remove cable guide with wiring harness from camshaft housing.
  • Release connector -2- and pull off.
  • Remove oil pressure switch - F1- -1-.
  • Pull connector and fuel supply line -arrows- off high-pressure pump.
  • Remove wiring guide -2- and remove connector -4- from Hall sender - G40-.
  • Loosen union nuts -3- and -1- of high-pressure line.
  • Pull out oil dipstick.
  • Loosen camshaft housing bolts from outside to inside, alternately and diagonally and remove.
  • Carefully lift camshaft housing off.

1.2.2 Installing

Condition

  • The pistons cannot be positioned at TDC.
  • Remove sealant residues from cylinder head and camshaft housing with a rotating brush, e.g. a hand drill with a plastic brush (wear eye protection).
  • Clean sealing surfaces carefully. They must be free of oil and grease.
  • Also prevent dirt and residual sealant from entering cylinder head.

If this is not the case, the camshaft clamp is defective and must be renewed.

Do not use any kind of hammer to position the camshaft clamp.

  • Turn inlet and exhaust camshafts until camshaft clamp - T10171 A- can be inserted into holes in camshaft to stop.
  • Screw in an M6 bolt hand-tight to secure camshaft clamp - T10171 A-, but do not tighten.

Sealing on cylinder head with no sealing ring in area of spark plug recess

  • Apply thin, even coat of sealant on clean camshaft housing sealing surface. See hatched area in illustration.

Sealing on cylinder head with sealing ring in area of spark plug recess

  • Place new seals into grooves in cylinder head.
  • Apply thin, even coat of sealant on clean camshaft housing sealing surface. See hatched area in illustration.
  • Do not apply sealant in area of -arrows-.

Sealing on cylinder head with machined chamfer in area of spark plug recess

  • Apply thin, even coat of sealant - D 154 103 A1- on clean camshaft housing sealing surface. See hatched area in illustration.
  • Apply sealant -D 176 600 A1- to the chamfer -arrows- of cylinder head.

The sealant bead must be 2 mm thick.

Proceed with extreme caution when fitting the camshaft housing onto the cylinder head in order to prevent the roller rocker fingers from sliding down!

  • When fitting camshaft housing onto cylinder head, first fit camshaft housing at angle shown in illustration onto dowel pins -arrows-.
  • Then, carefully lower camshaft housing in -direction of arrow- towards cylinder head.
  • Evenly tighten new camshaft housing securing bolts from inside to outside alternately and diagonally.

Ensure that camshaft housing is not canted. Specified torque 10 Nm + 1/4 turn (90°) further.

Further assembly is basically a reverse of the dismantling sequence. During this procedure, observe the following:

Specified torque

ComponentSpecified torque
Oil pressure switch - F1-20 Nm