Camshaft Timing Chain, Removing and Installing
Camshaft timing chain, removing and installing
Special tools, testers and auxiliary items required
^ Crankshaft holder 3242
^ Trim removal wedge 3409 (2x)
^ Old oil collecting and extracting device V.A.G 1782
^ Socket T10035
^ Camshaft locator T40046 (2x)
^ Setting gauge T40047
Special tools, testers and auxiliary items required
^ Polydrive key T40049
^ Drill 3.3 mm diameter (2x)
Removing
- Place oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
- Remove engine
- Disconnect engine and transmission
- Leave engine on scissor lift platform VAS 6131 or secure engine to assembly stand
- Remove covers for timing chains
- Install key T40049 at rear on crankshaft using 2 old bolts for dual-mass flywheel.
- Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.
^ Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.
- Rotate camshafts at hex head slightly back or forth if necessary so that camshaft locator T40046 can be inserted.
- If camshaft locator T40046 cannot be inserted, turn crankshaft 1 rotation (360) further.
- Remove camshaft locator T40046 again.
- Unscrew drain plug from upper section of oil pan.
- Screw crankshaft holder 3242 into hole (20 Nm). If necessary rotate crankshaft very slightly back and forth to completely center holder.
- Push glide track of chain tensioner for left timing chain in - direction of arrow - and pull off chain tensioner using a 3.3 mm diameter drill - item 1 -.
- Mark running direction of left timing chain in color.
- Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
- Remove camshaft chain sprocket, camshaft adjuster and timing chain.
- Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a 3.3 mm diameter drill - item 1 -.
- Mark running direction of right timing chain in color.
- Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
- Remove camshaft chain sprocket, camshaft adjuster and timing chain.
Installing
^ Secure crankshaft in TDC position using crankshaft holder 3242.
^ Drive chain for timing mechanism installed
Note:
^ Always replace bolts that are tightened to torque as well as O-rings and gaskets.
^ When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.
- Rotate inner part and outer part of both camshaft adjusters against each other up to lock position - arrows -.
^ Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt).
- Check whether camshafts of both cylinder heads stand in TDC position.
^ Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.
- Insert camshaft locator T40046 into camshafts of left cylinder head. Rotate camshafts back and forth at hex head if necessary.
- Insert camshaft locator T40046 into camshafts of right cylinder head. Rotate camshafts back and forth at hex head if necessary.
- Replace all four camshaft bolts.
- Assemble left timing chain with chain sprocket and camshaft adjuster.
- Loosely screw in bolts - 1 - and - 2 -.
^ Chain sprocket and camshaft adjuster must be still be able to be rotated on camshaft and must not be tipped.
- Assemble right timing chain with chain sprocket and camshaft adjuster.
- Loosely screw in bolts - 1 - and - 2 -.
^ Chain sprocket and camshaft adjuster must still be able to be rotated on camshaft and must not be tipped.
- Remove crankshaft holder 3242.
- Using key T40049, turn crankshaft approximately 30° in opposite direction of engine rotation - arrow -.
- Pull drill out of alignment hole, which loosens left chain tensioner.
- Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with it.
^ Light extra pressing of approximately 0.5 mm is permitted.
- Pull drill out of alignment hole, which loosens right chain tensioner.
- Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with it.
^ Light extra pressing of approximately 0.5 mm is permitted.
- Using key T40049, turn crankshaft in direction of engine rotation - arrow - to TDC ignition timing.
Note: If rotated unintentionally beyond TDC, turn back crankshaft again approximately 30° and set to TDC again.
- Screw crankshaft holder 3242 into hole (20 Nm). If necessary rotate crankshaft very slightly back and forth to completely center holder.
- Pre-tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head.
^ Tightening torque: 40 Nm.
- Secure camshaft position sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
- Place setting gauge T40047 on bolt - 1 -.
- Pre-tighten camshaft bolt - 2 - on intake camshaft.
^ Tightening torque: 40 Nm.
- Secure camshaft position sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
- Place setting gauge T40047 on bolt - 2 -.
- Pre-tighten camshaft bolt - 1 - on intake camshaft.
^ Tightening torque: 40 Nm.
- Remove setting gauge T40047.
- Pre-tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head.
^ Tightening torque: 40 Nm.
Note: Camshaft locators T40046 must not be used as counterholders for final tightening of camshaft bolts.
- Remove camshaft locators T40046 on both cylinder heads.
- Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque.
^ Tightening torque: 100 Nm plus 1/4 turn (90°).
- Secure camshaft position sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
- Place setting gauge T40047 on bolt - 1 -.
- Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque.
^ Tightening torque: 100 Nm plus 1/4 turn (90°).
- Secure camshaft position sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
- Place setting gauge T40047 on bolt - 2 -.
- Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque.
^ Tightening torque: 100 Nm plus 1/4 turn (90°).
- Remove setting gauge T40047.
- Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque.
^ Tightening torque: 100 Nm plus 1/4 turn (90°).
- Remove crankshaft holder 3242.
- Using key T40049 turn crankshaft two complete turns in direction of engine rotation - arrow - until crankshaft stands at TDC again.
^ Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.
- Screw crankshaft holder 3242 into hole (20 Nm). If necessary rotate crankshaft very slightly back and forth to completely center holder.
- Insert camshaft locator T40046 into camshafts of left cylinder head.
- Insert camshaft locator T40046 into camshafts of right cylinder head.
If camshaft locators cannot be inserted:
- Repeat adjustment.
- Pull out trim removal wedge 3409.
- Remove camshaft locator T40046 on both cylinder heads.
- Remove crankshaft holder 3242.
- Install sealing plug of TDC mark with new seal into upper section of oil pan.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install covers for timing chains.
- Install engine
- Add engine oil and check oil level
Tightening torques
