Camshaft Timing Chain, Removing From Camshafts
Camshaft Timing Chain, Removing from Camshafts
Special tools, testers and auxiliary items required
• Crankshaft Holder (3242)
• Torque Wrench (V.A.G 1332)
• Open Ring Spanner Insert, AF 24 mm (V.A.G 1332/9)
• Socket (T40058)
• Camshaft Clamp (T40070) (quantity: 2)
• Locking Pin (T40071) (Quantity: 2)
• Key (T40079)
Removing
• Engine/transmission assembly removed and mounted on scissor lift platform (VAS 6131 A).
• The camshaft timing chains remain on the engine in the following description.
- Remove the cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, refer to => [ 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 the (T40058) guide pins as follows:
• Small diameter - arrow 1 - points to engine.
• Large diameter - arrow 2 - points to socket.
- Using (T40058), rotate crankshaft in direction of engine rotation - arrow - to TDC.
• The threaded holes - arrows - in the camshafts must face upward.
- Mount the (T40070) on both cylinder heads and tighten the bolts - arrows - to 25 Nm.
• The (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
- Remove locking bolt - arrow - from upper section of the oil pan.
- Install the (3242) in the hole and tighten to 20 Nm. If necessary, rotate the crankshaft back and forth slightly 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 (T40071).
• The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.
- Install the right camshaft timing chain tensioner glide track all the way in using a screwdriver - 1 - and then secure the chain tensioner with the (T40071).
• The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.
- For re-installation, identify installation location of camshaft adjuster with paint.
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 the bolts - 1 - and - 2 - on left cylinder head and then remove both camshaft adjusters.
- For re-installation, identify installation location of camshaft adjuster with paint.
- Remove the bolts - 1 - and - 2 - on right cylinder head and then remove both camshaft adjusters.
Installing
• Replace the bolts which are being tightened with an additional turn.
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 (3242).
• Camshaft clamp (T40070) mounted on both cylinder heads and fastened to 25 Nm - arrows -.
• Reinstall left camshaft adjuster according to the mark applied during removal.
- Replace camshaft bolts.
- Install the camshaft timing chain on the drive chain sprocket and on the camshaft adjusters and then install the bolts - 1 - and - 2 - so that they are still loose.
• Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.
- Remove (T40071).
• Reinstall right camshaft adjuster according to the mark applied during removal.
- Replace camshaft bolts.
- Install the camshaft timing chain on the drive chain sprocket and on the camshaft adjusters and then install the bolts - 1 - and - 2 - so that they are still loose.
• Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.
- Remove (T40071).
• A second technician is needed for further work.
- Position (T40079) on intake camshaft adjuster at left cylinder head.
- Position (V.A.G 1332) with open ring spanner insert (V.A.G 1332/9) on (T40079).
- Pre-tension the camshaft adjuster in direction of - arrow - to 40 Nm and maintain the tension.
- Tighten bolts - 1 - on exhaust camshaft simultaneously to initial torque.
• Tightening specification: 60 Nm.
- Continue holding pretension on exhaust camshaft and pre-torque screw - 2 - on exhaust camshaft.
• Tightening specification: 60 Nm.
- Position (T40079) on exhaust camshaft adjuster at right cylinder head.
- Position (V.A.G 1332) with (V.A.G 1332/9) on (T40079).
- Pre-tension the camshaft adjuster in direction of - arrow - to 40 Nm and maintain the tension.
- Tighten bolts - 1 - on intake camshaft simultaneously to initial torque.
• Tightening specification: 60 Nm.
- Continue holding pretension on exhaust camshaft and pre-torque bolt - 2 - on exhaust camshaft.
• Tightening specification: 60 Nm.
- Remove (T40079).
- Remove (T40070) on both cylinder heads - arrows -.
- First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on left cylinder head to final torque.
• Tightening specification: 80 Nm plus an additional 90° turn.
- First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on right cylinder head to final torque.
• Tightening specification: 80 Nm plus an additional 90° turn.
- Remove (3242).
- Using (T40058) turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.
• If rotated unintentionally beyond TDC, turn back crankshaft again approximately 30° and set to TDC again.
• The threaded holes - arrows - in the camshafts must face upward.
- Mount the (T40070) on both cylinder heads and tighten the bolts - arrows - to 25 Nm.
• The (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
- Install the (3242) in the bore or groove and tighten it to 20 Nm.
• The (3242) must engage in the locating hole or groove on the crankshaft - 1 -. Repeat the adjustment if it does not.
- Remove camshaft locating tools on both cylinder heads.
- Remove (3242).
- Install TDC mark sealing plug with new seal in upper section of the oil pan.
The rest of installation is in reverse order of removal, note the following:
- Install left and right timing chain covers => [ Installing ] Left and Right Timing Chain Covers.
- Install the cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
Tightening Specifications
