Camshaft Timing Chains, Removing From Camshafts

Camshaft Timing Chains, Removing from Camshafts

• For the removal of the cylinder head or camshafts, it is sufficient to remove camshaft timing chains only from the camshafts. Chains remain on the engine; only the top covers at left and right are removed.

• Even if work is performed only on one of the cylinder heads, the procedure described must be followed, since then the valve timing at both cylinder heads must be adjusted.

Special tools, testers and auxiliary items required

• Locking pin (3242)

• Trim removal wedge (3409) (2x)

• Old oil collecting and extracting device (V.A.G 1782 )

• Multi-point socket (T10035)

• Camshaft locator (T40046) (qty. 2)

• Setting gauge (T40047)

• Old oil collecting and extracting device (V.A.G 1782 )

• Drill bit 3.3 mm in dia.(2x)

Procedure

• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Place old oil collecting and extracting device ( V.A.G 1782) under engine and drain engine oil.

- Remove engine. Refer to: Vehicles with manual transmission => [ Engine, Manual Transmission, Removing ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Removing ] Engine, Automatic Transmission, Removing and Installing.

- Leave engine with transmission installed on the scissor lift platform (VAS 6131 A).

- Disconnect electrical connection - 1 - at throttle valve control module (J338).





- Disconnect crankcase ventilation hose - 3 - at intake pipe.

• Disregard - 2 -.

- Remove electrical harness connectors - 1 -, - 2 -, - 5 - and - 6 - toward front from brackets on intake pipe.





- Disconnect connectors - 3 - and - 4 -.

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





- Disconnect connector strips - 1 - and - 5 - at fuel injectors.





- For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.

- Remove retaining bolts - 2 - and - 3 - for fuel rail pipe.

- Remove fuel rail pipe together with fuel injectors from intake manifold uniformly upward.

• Carefully protect the removed fuel injectors from contamination.

- Remove left rear engine lifting eye - arrows -.





- Remove intake manifold bolts - arrows - and remove it.





• Plug the intake ports of the cylinder head with clean rags.

- Remove cap - arrow - for oil filter housing.





- Remove oil filter element.

- Extract engine oil using old oil collecting and extracting device (V.A.G 1782) from oil filter housing.

• Place a rag around oil filter housing to catch escaping engine oil.

- Remove bolts - arrows -.





- Remove oil filter housing.

- Remove bolts - 1 - and - 2 -.





- Place old oil collecting and extracting device ( V.A.G 1782) underneath.

- Remove return pipe from power-steering pump - arrow -.

- Remove guide pipe for oil dipstick at cylinder head - arrow -, pull up and remove.





- Remove bolts - 1 - and - 2 -.





- Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

- Remove bolts - 1 - and - 2 -.





- Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

- Disconnect electrical connector - 2 - on the Engine Coolant Temperature (ECT) Gauge Sensor (G2)/ (G62).





- Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

- Remove bolts - 2 to 5 -.





- Remove rear coolant pipe.

• Ignore - 1 - and - 6 -.

- Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection system.





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





- Remove left heat shield - arrows -.





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





- Remove right heat shield - arrows -.





- Remove bolts - 5 - and - 6 - on left cylinder head.





- Disconnect electrical harness connectors - 1 to 4 -.

- Remove ignition coils - arrows -.

• Extractor (T40039) can be used for removal.

- Disconnect hose of crankshaft housing ventilation - arrow -.





- Remove left cylinder head cover bolts in sequence - 15 to 1 -.

- Remove cylinder head cover.

- Remove bolts - 5 - and - 6 - on right cylinder head.





- Disconnect electrical harness connectors - 1 to 4 -.

- Remove ignition coils - arrows -.

• Extractor (T40039) can be used for removal.

- Disconnect hose of crankshaft housing ventilation - arrow -.





- Remove right cylinder head cover bolts in sequence - 15 to 1 -.

- Remove cylinder head cover.

- Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 (G163) on left cylinder head.





- Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor (G40) on right cylinder head.





- Remove Ground (GND) wire on right cylinder head - arrow -.





- Set wiring harness aside.

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





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





- 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, rotate crankshaft 1 rotation (360°) further.

- Remove camshaft locator (T40046) again.

- Remove drain plug from upper section of oil pan.

- Install crankshaft holder (3242) in the hole (20 Nm). Rotate camshaft back and forth slightly if necessary to completely center the holder.





- Push glide track of chain tensioner for left timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm in dia. - 1 -.





• In the following illustration, the timing mechanism is depicted with covers completely removed.

- Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket (T10035).





- Remove camshaft chain sprocket and camshaft adjuster.

• Camshaft timing chain remains on engine.

• Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

- Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm in dia. - 1 -.





- Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket (T10035).





- Remove camshaft chain sprocket and camshaft adjuster.

• Camshaft timing chain remains on engine.

• Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

Installing

• Secure crankshaft in TDC position using crankshaft holder (3242).

• 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.

• During installation, all cable ties must be re-installed at the same location.

- 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, to do so rotate camshafts back or forth at hex head if necessary.





- Insert camshaft locator (T40046) into camshafts of right cylinder head, to do so rotate camshafts back or 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 able to still be rotated on camshaft and must not tip.

- Assemble right timing chain with chain sprocket and camshaft adjuster.





- Loosely screw in bolts - 1 - and - 2 -.

• Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip

- Remove crankshaft holder (3242).





- Rotate crankshaft 30° in opposite direction of engine rotation - arrow -.





- Pull drill out of alignment hole, which loosens the left chain tensioner.

- Insert trim removal wedge (3409) as shown in illustration and bring chain tensioner into contact with trim removal wedge (3409).





• Lightly pressing in an extra 0.5 mm is permitted.

- Pull drill out of alignment hole, which loosens the right chain tensioner.

- Insert trim removal wedge (3409) as shown in illustration and bring chain tensioner into contact with trim removal wedge (3409).





• Lightly pressing in an extra 0.5 mm is permitted.

- Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.





• If rotated unintentionally beyond TDC, turn back crankshaft again approximately 30° and set to TDC again.

- Install the crankshaft holder (3242) in the hole (20 Nm). Rotate the camshaft back and forth slightly if necessary to completely center the holder.





- Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening specifications.





• Tightening Specifications: 40 Nm.

- Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge (T40047).





- Place setting gauge on bolt - 1 -.

- Tighten camshaft bolt - 2 - on intake camshaft to initial tightening specifications.

• Tightening Specifications: 40 Nm.

- Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge (T40047).





- Place setting gauge on bolt - 2 -.

- Tighten camshaft bolt - 1 - on intake camshaft to initial tightening specifications.

• Tightening Specifications: 40 Nm.

- Remove setting gauge.

- Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening specifications.





• Tightening Specifications: 40 Nm.

• Camshaft locators must not be used as counterholder 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 specifications.





• Tightening Specifications: 100 Nm plus an additional 90° ( 1/4 turn).

- Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge (T40047).





- Place locator on bolt - 1 -.

- Tighten camshaft bolt - 2 - on intake camshaft to final tightening specifications.

• Tightening Specifications: 100 Nm plus an additional 90° ( 1/4 turn).

- Secure Hall 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 specifications.

• Tightening Specifications: 100 Nm plus an additional 90° ( 1/4 turn).

- Remove setting gauge (T40047).

- Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening specifications.





• Tightening Specifications: 100 Nm plus an additional 90° ( 1/4 turn).

- Remove crankshaft holder (3242).





- Turn crankshaft two complete rotations 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.





- Install the crankshaft holder (3242) in the hole (20 Nm). Rotate the camshaft back and forth slightly if necessary to completely center the 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 marking with new sealing ring into upper section of oil pan.

The rest of installation is in reverse order of removal, note the following:

- Install covers for timing chains => [ Installing ] Timing Chain Covers.

- Install engine. Refer to: Vehicles with manual transmission => [ Engine, Installing ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Installing ] Engine, Automatic Transmission, Removing and Installing.

- Add engine oil and check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.

Tightening Specifications





* 90° corresponds to one quarter rotation.

* Replace bolts.