Camshaft Timing Chains, Removing from Camshafts
Camshaft Timing Chains, Removing from Camshafts
Special tools, testers and auxiliary items required
• Locking pin (3242)
• Torque wrench (VAG 1332)
• Assembly tool (VAG 1332/9)
• Adapter (T40058)
• Camshaft clamp (T40070), Quantity: 2
• Locking pin (T40071), Quantity: 2
• Adapter (T40079)
Removing
• According to the following procedure, 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 engine. Refer to => [ Engine, Removing ] Engine, Removing.
- Separate engine and transmission. Refer to => [ Separating transmission from engine ] Engine, Removing.
- Secure engine on engine and transmission holder (VAS 6095). Refer to => [ Engine, Securing on Engine and Transmission Holder ] Engine, Securing on Engine and Transmission Holder.
- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Service and Repair.
- Remove the cylinder head cover: Left, refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover and right, refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Insert socket (T40058) adapter so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.
- Using socket (T40058), rotate crankshaft in direction of engine rotation - arrow - to Top Dead Center (TDC).
• The threaded holes - arrows - in the camshafts must face upward.
- Mount the camshaft clamp (T40070) on both cylinder heads and tighten the bolts - arrows - to 25 Nm.
• The camshaft clamp (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
- Remove the locking bolt - arrow - from upper part of oil pan.
- Install the crankshaft holder (3242) into the hole and tighten to 20 Nm, if necessary rotate crankshaft very slightly back and forth to completely center the holder.
CAUTION!
Do not turn crankshaft - 1 - while touching Top Dead Center (TDC) hole with finger - Risk of injury.
- Press left camshaft timing chain tensioner guide rail inward with a screwdriver - 1 - until seated 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 guide rail inward with a screwdriver - 1 - until seated 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.
- Mark the allocation of the camshaft adjuster to the camshaft for reinstallation.
- Remove bolts - 1 - and - 2 - on left cylinder head and remove both camshaft adjusters.
- Mark the allocation of the camshaft adjuster to the camshaft for reinstallation.
- Remove bolts - 1 - and - 2 - on right cylinder head and remove both camshaft adjusters.
Installing
• Replace bolts which have been tightened to specifications.
CAUTION!
When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.
• 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 tightened to 25 Nm - arrows -.
• Reinstall left camshaft adjuster according to the mark applied during removal.
- Replace camshaft bolts.
- 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 right camshaft adjuster according to the mark applied during removal.
- Replace camshaft bolts.
- 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).
• A 2nd technician is needed for further work.
- Position adapter (T40079) on intake camshaft adjuster at left cylinder head.
- Position torque wrench (VAG 1332) with open ring spanner insert (VAG 1332/9) on adapter (T40079).
- Pretension the camshaft adjuster in the - direction of the arrow - to 40 Nm and maintain the tension.
- Tighten bolt - 1 - on exhaust camshaft simultaneously to initial specification.
• Tightening specification: 60 Nm.
- Continue holding pretension on exhaust camshaft and pre tighten bolt - 2 - on exhaust camshaft.
• Tightening specification: 60 Nm.
- Position adapter (T40079) on exhaust camshaft adjuster at right cylinder head.
- Position torque wrench (VAG 1332) with open ring spanner insert (VAG 1332/9) on adapter (T40079).
- Pretension the camshaft adjuster in the - direction of the arrow - to 40 Nm and maintain the tension.
- Tighten bolt - 1 - on intake camshaft simultaneously to initial specification.
• Tightening specification: 60 Nm.
- Continue holding pretension on exhaust camshaft and pre tighten bolt - 2 - on exhaust camshaft.
• Tightening specification: 60 Nm.
- Remove adapter (T40079).
- Remove camshaft clamp (T40070) from both cylinder heads - arrows -.
- First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on left cylinder head to final specification.
• Tightening specification: 80 Nm + 90° (1/4 turn) additional turn.
- First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on right cylinder head to final specification.
• Tightening specification: 80 Nm + 90° (1/4 turn) additional turn.
- Remove crankshaft holder (3242).
- Using socket (T40058) turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft is at TDC again.
• If rotated unintentionally beyond TDC, turn back crankshaft again approximately 30 degrees and set to TDC again.
• The threaded holes - arrows - in the camshafts must face upward.
- Mount the camshaft clamp (T40070) to both cylinder heads and tighten the bolts - arrows - to 25 Nm.
• The camshaft clamp (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
- Install crankshaft holder (3242) into the hole 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).
- Install TDC mark sealing plug with new seal in upper part of oil pan.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Service and Repair.
- Install cylinder head cover: Left, refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover and right, refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
Tightening Specifications
