Removing

Timing chains, removing from camshaft

Note:
^ For removal of cylinder head or camshafts, it is sufficient to merely detach timing chains from camshafts. Leave chains on engine. Transmission is not detached.
^ Compliance with the procedure described is essential even if work is only to be performed on one of the cylinder heads, as the timing then has to be adjusted at both cylinder heads.

Special tools and equipment

^ Locating bolt 3242

^ Trim removal wedge 3409 (2x)

^ V.A.G. 1358 A or V.A.G. 1782

^ Socket attachment T1 0035
^ Camshaft locator T40046 (2x)
^ Locator for Hall sender rotor ring T40047
^ Drill bit 3.3 mm diameter (2x)
^ Oil collector

Sequence of operations
- Remove engine
- Set down engine/transmission assembly on workbench or trolley and secure in position with wooden blocks.

WARNING:
^ Engine transmission assembly must be secured to avoid risk of accident
^ Never set down engine and transmission on sump or oil pan.

- Detach lifting tackle 3033 from engine.

- Disconnect connector -1- at throttle valve control module -J338-.
- Detach crankcase breather hose -3- at intake manifold.

Note: Ignore item -2-.

- Pull connectors -1 -, -2-, -5- and -6- forward off holders at intake manifold.
- Disconnect connectors -3- and -4-.

- Disconnect vacuum hose (arrow) at T-piece.

- Disconnect connector consoles -1- and -5- at injectors.
- Detach vacuum line -4- at fuel pressure regulator.
- Remove fuel rail retaining bolts -2- and -3-.
- Lift fuel rail together with injectors evenly off intake manifold.

Note: Make sure injectors removed are properly protected against contamination.

- Remove left rear engine lifting eye bolts (arrows).

- Unscrew bolts (arrows) and take out intake manifold.

Note: Seal intake ducts in cylinder heads with clean cloths.

- Unscrew cap (arrow) for oil filter housing.
- Take out oil filter element.
- Use VAG 1358 A or VAG 1782 to extract engine oil from oil filter housing.

Note: Place cloth around oil filter housing to catch engine oil emerging.

- Remove bolts (arrows).
- Detach oil filter housing.

- Disconnect connector -1- at left engine mount.
- Remove nut -2- and detach engine mount.

- Remove bolts -1 -and -2-.
- Detach return line from power steering pump (arrow).

- Unscrew guide tube bolt (arrow) for dipstick at cylinder head and lift off.

- Remove bolts -1 -and -2-.
- Unfasten hose clamps (arrows) and detach left coolant pipe from coolant hoses.

- Remove bolts -1 -and -2-.
- Unfasten hose clamps (arrows) and detach right coolant pipe from coolant hoses.

- Disconnect connector -2- at engine coolant temperature (ECT) sensor G2-/-G62-.
- Remove nut -1- and detach wiring harness at rear coolant pipe.

- Remove bolts -2- to -5-.
- Detach rear coolant pipe.

Note: Ignore items -1- and -6-.

- Remove bolts -1- to -4- for combination valves for secondary air system.

- Disconnect connectors -1 -to -4-.
- Set wires aside.

Note: Illustration shows connectors in installation position.

- Unscrew front exhaust pipe nuts -1- to -3- from left exhaust manifold.

- Disconnect connectors -1 -to -4-.

Note: Illustration shows connectors in installation position.

- Remove bolt (arrow) at lug for right front exhaust pipe.

- Unscrew front exhaust pipe -nuts -1- to -3- from right exhaust manifold.

- Remove nuts -1- to -12- and detach left exhaust manifold.

- Remove bolts (arrows) and detach left heat shield.

- Remove nuts -1- to -12- and detach right exhaust manifold.

- Remove bolts (arrows) and detach right heat shield.

- Remove bolts -5- and -6- at left cylinder head.
- Disconnect connectors -1 -to -4-. - Pull out ignition coils (arrows).

Note: Special tool T10094 can be used for removal.

- Detach crankcase breather hose (arrow).
- Remove bolts for left cylinder head cover in sequence -15- to -1 -.
- Detach cylinder head cover.

- Remove bolts -5- and -6- at right cylinder head.
- Disconnect connectors -1 -to -4-.
- Pull out ignition coils (arrows).

Note: Special tool T10094 can be used for removal.

- Detach crankcase breather hose (arrow).
- Remove bolts for right cylinder head cover in sequence -15- to -1 -.
- Detach cylinder head cover.

- Disconnect connector (arrow) for camshaft position (CMP) sensor 2G163- at left cylinder head.

- Unplug connector (arrow) for camshaft position (CMP) sensor -G40-at right cylinder head.

- Unscrew ground (GND) cable (arrow) at right cylinder head.
- Move aside wiring harness.

- Remove bolts -1- to -6- and detach left timing chain cover.

- Remove bolts -1- to -6- and detach right timing chain cover.

- Turn crankshaft in direction of engine rotation (arrow) to no. 8 cyl. TDC ignition point ...

- ... slots (arrows) at front of camshafts must be parallel to and level with top edge of cylinder head.

- If necessary, turn camshafts slightly in one direction or the other at hex to permit insertion of camshaft locator T40046.
- If camshaft locator cannot be inserted, give crankshaft 1 complete turn (360°).
- Detach camshaft locator again.
- Remove screw plug out of upper part of oil pan.

- Screw locating bolt 3242 into hole (20 Nm); if necessary, turn crankshaft back and forth slightly to fully center bolt.

- Press tensioner guide rail for left timing chain in direction of (arrow) and set chain tensioner with 3.3 mm diameter drill bit item -1 -.

Note: All timing mechanism covers have been removed in the following illustrations.

- Remove bolts -1- and -2- for camshaft chain sprocket/cam shaft adjuster with socket attachment T1 0035.
- Detach camshaft chain sprocket and camshaft adjuster.

Note:
^ Leave camshaft timing chain on engine.
^ Camshaft sprocket bolts must be loosened at both cylinder heads even if only one of the cylinder heads is to be removed.

- Press tensioner guide rail for right timing chain in direction of (arrow) and set chain tensioner with 3.3 mm diameter drill bit item -1 -.