Camshaft Timing Chains

Camshaft Timing Chains

Special tools, testers and auxiliary items required

• Locking Pin (3242)

• Torque Wrench (V.A.G 1332)

• Assembly Tool (V.A.G 1332/9)

• Adapter (T40058)

• Camshaft Clamp (T40070), qty. 2

• Locking Pin (T40071), qty. 2

• Wrench (T40079)

Removing

• According to the following description, the timing chains for camshafts remain on engine.

• 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.

- Remove cylinder head covers. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Insert Adapter (T40058) into guide pins as follows:

• Small diameter - arrow 1 - points to engine.

• Large diameter - arrow 2 - points to socket.

- Using Socket (T40058), rotate crankshaft in direction of engine rotation - arrow - to "TDC".

• The threaded holes - arrows - in the camshafts must face upward.

- Mount the Camshaft Locating Tool (T40070) on both cylinder heads and tighten bolts - arrows - to 25 Nm.

• The Camshaft Locating Tool (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.

- Remove locking bolt - arrow - from upper section of oil pan.

CAUTION!
Risk of injury when touching "TDC" hole with finger.

• Do not rotate crankshaft - 1 -.

- Install Crankshaft Holder (3242) into hole to 20 Nm, if necessary rotate crankshaft very slightly back and forth to completely center the holder.

- Press left camshaft timing chain tensioner glide track inward with a screwdriver - 1 - as far as stop and secure chain tensioner with Locking Pin (T40071).

• The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

- Press right camshaft timing chain tensioner glide track inward with a screwdriver - 1 - as far as stop and secure chain tensioner with Locking Pin (T40071).

• The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

CAUTION!
The engine could be destroyed.

• To prevent small parts from accidentally entering the engine through the opening in the timing chain compartment, cover the opening with a clean cloth.

- Remove bolts - 1 and 2 - on left cylinder head and remove both camshaft adjusters.

- For re-installation, identify installation location of camshaft adjuster with paint.

- Remove bolts - 1 and 2 - on right cylinder head and remove both camshaft adjusters.

Installing

• Tightening specifications. Refer to => [ Camshaft Timing Chain Assembly Overview ] Camshaft Timing Chain Assembly Overview, => [ Upper Oil Pan Section Assembly Overview ] Upper Oil Pan Section Assembly Overview.

• Replace bolts which have been tightened to torque.

• Replace locking bolt O-ring.

CAUTION!
Risk of damaging valves and piston crowns.

• If camshafts are rotated, crankshaft may not rest with any piston at "TDC".

• Drive chain for timing mechanism installed. Refer to => [ Timing Mechanism Drive Chain ] Timing Mechanism Drive Chain.

• Secure crankshaft in "TDC" position using Crankshaft Holder (3242).

• Camshaft Clamp (T40070) mounted on both cylinder heads and fastened to 25 Nm - arrows -.

- Reinstall camshaft adjuster on left cylinder head according to the mark applied during removal.

- Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in the bolts - 1 and 2 -.

• Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

- Remove Locking Pin (T40071).

- Reinstall camshaft adjuster on right cylinder head according to the mark applied during removal.

- Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in the bolts - 1 and 2 -.

• Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

- Remove Locking Pin (T40071).

- Position Key (T40079) on intake camshaft adjuster at left cylinder head.

- Position Torque Wrench (V.A.G 1332) with Open Ring Spanner Insert (V.A.G 1332/9) on Key (T40079).

- Have a second technician pre-tension camshaft adjuster to 40 Nm in direction of - arrow -.

- Tighten bolts as follows while camshaft adjuster is held under pre-tension:

- Position Key (T40079) on exhaust camshaft adjuster at right cylinder head.

- Remove Key (T40079).

- Remove Camshaft Clamps (T40070) on both cylinder heads - arrows -.

- Tighten camshaft adjuster bolts on left cylinder head as follows:

- Tighten camshaft adjuster bolts on right cylinder head as follows:

- Remove Crankshaft Holder (3242).

- Using Socket (T40058) turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at "TDC" again.

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

• The threaded holes - arrows - in the camshafts must face upward.

- Mount the Camshaft Locating Tool (T40070) on both cylinder heads and tighten the bolts - arrows - to 25 Nm.

• The Camshaft Locating Tool (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.

- Install Crankshaft Holder (3242) in bore and tighten to 20 Nm.

• The Crankshaft Holder (3242) must engage in the locating hole of the crankshaft - 1 -, otherwise repeat the adjustment.

- Remove camshaft locating tools on both cylinder heads.

- Remove Crankshaft Holder (3242).

- Tighten "TDC" marking locking bolt.

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

- Install left and right timing chain covers => [ ] Left and Right Timing Chain Covers.

- Install cylinder head covers. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.