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Author Topic: TDI camshaft Cover/Rocker cover removal  (Read 6296 times)

Offline g4dget

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TDI camshaft Cover/Rocker cover removal
« on: November 13, 2015, 05:24:48 PM »
Need help as i having a mare!!!!
i need to remove my camshaft cover to investigate an injector issue but i cannot seem to remove one of the bolts.
The bolts is the one situated under the EGR valve on the left had side of the engine (no4) end. i cant get access to the bolt with any of my tools. i have removed the EGR hard pipework, moved the fuel filter and still i cant get on it. does the EGR need to be removed or is there something obvious i'm missing??

Offline Mirez

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #1 on: November 13, 2015, 06:20:45 PM »
The EGR valve is only held on with 3 allen bolts, I don't recall needing to remove it but then I had a multitude of tools at my disposal. For the sake of sanity I would just remove it :)
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
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Offline Chrispb

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #2 on: November 13, 2015, 08:00:08 PM »
Seem to remember a ¼ drive socket set is small enough to get in there.
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2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

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Offline g4dget

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #3 on: November 13, 2015, 09:05:41 PM »
I toyed with removing the egr but the bolts aren't easy to get to and you have to remove additional items to gain access to to last bolt.  :(

i didn't have a 1/4 set available at the time but will try that

Online johnnyroper

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #4 on: November 13, 2015, 10:42:51 PM »
After recently having head off mine I can confirm you do need to remove egr before removing cam cover, bit fiddly to get pipe off and the 3 Allen bolts. 1/4 drive socket set is what's needed as my 3/8 drive had no chance of getting in there.
Funnily enough got to re visit mine tomorrow due to cam cover gasket leak!

Offline g4dget

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #5 on: November 14, 2015, 12:30:59 PM »
not the answer i wanted but if i must then off it comes. suppose i could clean the egr at the same time.

Online johnnyroper

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #6 on: November 14, 2015, 04:06:46 PM »
Certainly worth doing that mine was full of crap,left it soaking in paraffin to break it all up. Looked like new when refitting bet it don't now after a few thousand miles!

Offline bigjeeze

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #7 on: November 14, 2015, 04:48:06 PM »
I had the same problem - although mine was in re fitting.  I just used a small grinding tool to remove a small amount of the finning on the EGR so that my socket would go on.

What an absolute pig!
On the Square

Online johnnyroper

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Re: TDI camshaft Cover/Rocker cover removal
« Reply #8 on: November 16, 2015, 09:30:48 AM »
Also worth inspecting camshaft for lobe wear while cover is off along with a check of the timing belt if not been checked/replaced recently.

 

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