Removal and installation the camshaft housing (VW Passat B6)

Note: This engine has camshafts located in the camshaft housing. The timing cover must be removed before removing the camshaft housing.

Note: The camshaft housing seating surface must not be machined.

Removal

First, you need to check whether the car has a radio with coding. If so, you should find out the security code.

Disconnect the ground wire from the battery with the ignition off.

Remove the timing cover.

Turn the crankshaft to TDC of the first cylinder, then turn the crankshaft back against the direction of engine rotation by approximately 45° and remove the camshaft sprockets with the timing chain.

Remove the EGR valve and unscrew the camshaft covers.

Disconnect the low pressure fuel pressure sensor plug.

Unscrew the ground cable from the camshaft housing.

Remove the ignition coils. Use a puller to do this.

Remove the wiring box with the wiring harness from the camshaft housing.



Disconnect the plug and fuel supply line from the high pressure pump (Fig. 2.39).

Remove the guide and remove the clamp from the high pressure line.

Note: When loosening the union nuts, hold the threaded connections on the high pressure pump and the lower part of the intake manifold with a wrench.

Unscrew union nuts 3 and 1 of the high pressure line.

Disconnect the plug from the Hall sensor.

Remove the dipstick.

Remove the lower portion of the intake manifold.

Unscrew the left hanging eye.

Loosen and remove the camshaft housing mounting bolts from the edges to the center, alternating crosswise.

Carefully lift the camshaft housing.

Installation

Remove any remaining sealant from the cylinder head and camshaft housing with a standard sealant remover.

Note: Pistons should not be at TDC.

Prevent dirt and sealant residue from getting into the cylinder head.

Clean the mounting surfaces thoroughly. They must be free of oil and grease.

Rotate the intake and exhaust camshafts until the camshaft locking pin fits into the camshaft holes as far as it will go.

To secure the retainer, screw in the M6 bolt by hand; without delay.



Apply sealant to the clean camshaft housing mounting surface in a thin, even bead, see shaded area in Figure 2.40.

Note: The sealant bead should not be too thick, otherwise excess sealant may enter the oil passages, causing engine damage.

Make sure that all roller levers are correctly applied to the ends of the valve stems 1 and clipped into the corresponding support element 2 (Fig. 2.41).

Before installing the camshaft housing, screw two spacer bolts (M6x80) into the cylinder head.

Carefully place the camshaft housing vertically on top of the spacer bolts and cylinder head dowel pins.

Note: Avoid contact of oil with adjacent surfaces.

Tighten the new camshaft housing mounting bolts evenly in a crisscross pattern, alternating from the center outward.

Make sure that the camshaft housing is not warped. Tightening torque 10 Nm + tighten by 1/4 turn (90°)

Note: After installing the camshaft housing, allow the sealant to dry for approximately 30 minutes.

Adjust the valve timing.

Further installation is carried out in reverse order.

Install the timing cover.

Connect the fuel lines.

Install the EGR valve

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