2005 Volkswagen JETTA

Submodel: 2.5 | Engine Type: L5 | Liters: 2.5

Fuel Delivery: FI | Fuel: GAS

1.8L Engine
To Remove:
1.

Disconnect the negative battery cable

2.

Lock carrier in service position

3.

Remove or disconnect the following:

Toothed belt from camshaft sprocket
Engine cover
Secondary air combination valve
Connector at camshaft adjuster
Cylinder head cover
Camshaft sprocket bolt (Counterhold with SST 3036 or equivalent).
Cam shaft sprocket
Camshaft position sensor
CAUTION
Excessive tightening of chain tensioner holder can damage camshaft adjuster.
Camshaft chain tensioner holder installed

4.

Secure camshaft adjuster with chain tensioner holder 3366 or equivalent

Camshafts at TDC

5.

Re-check TDC position of camshafts:

6.

Mark on the two camshafts must be in line with arrows on bearing caps

7.

Clean chain and camshaft sprockets opposite two arrows on bearing caps and mark installation position using colored markings

8.

The distance between the two arrows or between colored markings is 16 rollers on the drive chain
Distance between the colored markings

9.

The notch on exhaust camshaft is offset slightly toward inside in relation to chain roller A
NOTE: Do not mark chain with a center punch or by making a notch, etc.
Four cylinder camshaft bearing cap ID

10.

Remove or disconnect the following:

Bearing caps three and five on intake and exhaust camshafts
Double bearing cap
Both bearing caps on intake and exhaust camshaft chain sprockets
Bolts securing camshaft adjuster

11.

Loosen bearing caps two and four of intake and exhaust camshafts alternately in diagonal sequence and remove

12.

Remove intake and exhaust camshafts together with camshaft adjuster

To Install:
Sealant location

1.

Replace rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant to shaded areas as shown in illustration

2.

Install drive chain on camshaft sprockets as follows:

If old chain is used install chain so that colored markings are in line with notches
New chain position

If new chain is used distance between notches one and two on camshafts must be 16 rollers on chain. Illustration shows exact positions of 1st and 16th rollers on
sprockets
The notch one is offset slightly toward inside in relation to chain roller A
Insert camshaft adjuster between drive chain (two technicians are needed).
Locate camshafts together with drive chain and camshaft adjuster in cylinder head
Oil camshaft journal surface
Dowel sleeves for bearing caps and camshaft adjuster must be installed in cylinder head
When installing bearing caps ensure that identification mark is readable from intake side of cylinder head
Torque camshaft adjuster bolts to 89 in-lbs (10 Nm). Watch position of dowel sleeves
Four cylinder camshaft bearing cap ID

3.

Torque bearing caps two and four of intake and exhaust camshafts alternately in diagonal sequence to 89 in-lbs (10 Nm). Watch position of dowel sleeves

4.

Install both bearing caps on intake and exhaust camshaft chain sprockets

5.

Check correct setting of camshafts:

6.

The two markings on camshafts must be in line with the two arrows on bearing caps

7.

The distance between the two arrows on bearing caps or between colored markings is 16 rollers on the drive chain

8.

The notch on exhaust camshaft is offset slightly toward inside in relation to chain roller A

9.

Remove chain tensioner holder 3366

Sealant location on double bearing cap

10.

Apply thin coat of sealant to shaded area on double bearing cap

11.

Install double bearing cap; torque bolts to 89 in-lbs (10 Nm). Watch position of dowel sleeves

12.

Install or connect the following:

Remaining bearing caps; torque bolts to 89 in-lbs (10 Nm). Watch position of dowel sleeves
Oil seals for intake and exhaust camshafts
NOTE: Narrow web of camshaft sprocket must face outward and marking for TDC No. 1 cylinder must be visible from front.
Camshaft sprocket
Bolt for camshaft sprocket; torque to 48 ft-lbs (65 Nm). Use Counterhold 3036 or equivalent
Camshaft position sensor; torque rotor ring to 18 ft-lbs (25 Nm) and housing to 89 in-lbs (10 Nm)
Cylinder head cover
Set crankshaft and camshaft to TDC No. 1 cylinder

13.

Align marking on camshaft sprocket with marking on cylinder head cover

14.

Align marking on vibration damper with marking on bottom section of toothed belt guard
CAUTION
The crankshaft must not be at TDC when camshaft is rotated. Otherwise there is a risk of damage to valves and piston crowns.

15.

Install toothed belt

CAUTION
After installing camshafts, engine must not be started for approximately 30 minutes. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). After
working on valve gear, rotate crankshaft carefully at least two rotations, to ensure that none of the valves make contact when starter is operated.

2.0L Engine
To Remove:
1.

Remove the engine cover.

2.

Remove the upper intake manifold.

3.

Remove the upper timing belt cover.

4.

Turn the crankshaft to align the mark on the camshaft sprocket with the mark on the rear belt cover. This is TDC No. 1.

5.

Loosen the timing belt tensioner and remove the belt from the camshaft sprocket.

6.

Turn the crankshaft backward slightly.

7.

Remove the camshaft sprocket. Hold the sprocket with a tool such as 3415.

8.

Remove the cylinder head cover.

9.

Remove camshaft bearing caps 5, 1 and 3. Remove bearing caps 2 and 4 by gradually removing the bolts diagonally and alternately.

10.

Remove the camshaft.

To Install:
NOTE: Make sure pistons are not at TDC.
1.

Apply new engine oil to the camshaft. Install the camshaft on the cylinder head. Make sure the lobes on cylinder No. 1 are facing up.

2.

Coat the sealing surfaces of bearing cap 1 with a small amount of sealant AMV17400401 or equivalent.

3.

Install the bearing caps in their original positions. The caps are offset, install them in the correct direction.

4.

Tighten bearing caps 2 and 4 alternately and diagonally to 15 ft-lbs (20 Nm).

5.

Tighten bearing caps 3, 1 and 5. Tighten bolts to 15 ft-lbs (20 Nm).

CAUTION
Do not turn the camshaft if the crankshaft is at TDC.

6.

Install the camshaft pulley. Tighten bolt to 74 ft-lbs (100 Nm).

7.

Install the timing belt on the camshaft sprocket.

8.

Install the timing belt cover.

CAUTION
Do not start the engine for at least 30 minutes if new lifters were installed. Allow the lifters to bleed down so the valves will not hit the pistons.

2.8L Engine
To Remove:
1.

Remove or disconnect the following:

Timing Belt
Camshaft gears
Combination valve for Secondary Air Injection
Right-side cylinder head:
Electrical harness connectors at Camshaft Position (CMP) Sensor
Bracket with idler roller
Toothed belt guard at rear right
Left-side cylinder head:
Toothed belt guard at rear left
Both cylinder heads:
T40030 or equivalent camshaft adjuster gauge from camshafts
Housing for camshaft adjustment valves
Housing for Camshaft Position (CMP) sensor
Camshaft guide frame bolt loosening sequence

2.

Loosen bolts of guide frame in the sequence of the numbers and follow arrows
Press off guide frame

3.

Press off guide frame with 6mm bolts (arrows)

4.

Carefully remove guide frame and camshafts

To Install:
1.

Replace gaskets and O-rings

2.

Align crankshaft using T 40026 locking pin

3.

Oil camshaft journal surface

4.

Left-side cylinder head:

Left cylinder head camshaft position

5.

Insert camshaft into cylinder head as depicted in illustration

6.

Cams at cylinder five point downward evenly (arrows)

7.

Right-side cylinder head:

Right cylinder head camshaft position

8.

Insert camshaft into cylinder head as depicted in illustration

9.

Cams at cylinder three point upward evenly (arrows)

10.

Both cylinder heads:

NOTE: Sealant bead must be applied according to exact specifications otherwise excess sealant could get into the camshaft bearings.
Sealant location for guide frame

11.

Apply sealant to clean sealing surface of guide frame as shown in illustration

12.

Thickness of sealant bead:

13.

Distance of sealant bead to the camshaft bearings at the specified locations

14.

In addition sealing surfaces around the spark plug bores obtain a sealant ring each, I to K.

15.

Immediately set guide frame in place and align using T40029 locating pin or equivalent

Approximately 1.2 mm

A to H: at least 5mm

Guide frame bolt tightening sequence

16.

Tighten bolts of guide frame in the sequence of the numbers and follow arrows uniformly by hand

17.

Guide frame must make full contact with cylinder head surface

18.

Torque bolts of guide frame to final torque of 89 in-lbs (10 Nm)

19.

Using T10055 extractor remove T40029 locating pin from cylinder head

20.

Left-side cylinder head:

21.

Insert T40030 or equivalent camshaft adjuster gauge at camshafts

22.

Spread T40030 or equivalent camshaft adjuster gauge with threaded shaft; torque to 89 in-lbs (10 Nm) until it is seated without axial play

23.

Right-side cylinder head:

24.

Install exhaust camshaft gear

Rotate camshafts for right cylinder head

25.

Turn exhaust camshaft arrow A and intake camshaft arrow B 30 in direction of arrow until the cams (arrows) of cylinder three at intake and exhaust camshafts are as shown
in the illustration
Number 3 cam lobe position

26.

Insert T40030 or equivalent camshaft adjuster gauge at camshafts

27.

Remove exhaust camshaft gear again

28.

Install Camshaft Position (CMP) Sensor housing; torque bolts to 89 in-lbs (10 Nm)
Camshaft piston ring position

29.

Check if the piston rings are installed at the camshafts and if the piston ring ends are engaged with each other

30.

If necessary engage the ends of the installed piston rings

31.

Install camshaft adjustment housing; torque bolts to 89 in-lbs (10 Nm)

32.

Install or connect the following:

32.

Install or connect the following:

Combination valve for Secondary Air Injection
Toothed belt guard at rear left
Toothed belt guard at rear right
Bracket with idler roller
Electrical harness connectors at Camshaft Position (CMP) Sensor
Toothed belt

CAUTION
After installing camshafts engine must not be started for approximately 30 minutes. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). After working
on valve gear, rotate crankcase carefully (at least 2 rotations) to ensure that none of the valves make contact when starter is operated.