Timing Chain: Service and Repair

Camshaft Adjuster / Camshaft Drive Chain

Special tools, testers and auxiliary items required
• Socket (T40080)
• Camshaft clamp (T10252)
• Toothed belt tensioner (T10020)
• Locking pin (T10115)
• Torque wrench (40-200 Nm) (VAG 1332)
• Hose clamps up to 25 mm diameter (3094)

Removing

- Remove the cylinder head cover. Refer to --> [ Cylinder Head Cover ] Service and Repair.
- Remove the high pressure pump - 1 -. Refer to --> [ High Pressure Pump ] High Pressure Pump.





- Disconnect the vacuum line - 7 - from the vacuum pump.
- Disengage and disconnect the electrical connector - 3 -.
- Clamp off the coolant hose using the (3094) and disconnect the hose from the coolant pipe - 4 -.
- Disconnect the coolant pipe - 4 - from the engine.
- Remove the wiring harness from the brackets - 5 -.
- Remove the cover - 2 - for the camshaft adjuster.





- Bring the mark on the camshaft gear to alignment with the mark on the toothed belt guard. Recesses - arrows - now point to each other vertically.





- Install and secure the (T10252) as shown with bolts - arrows -.
- Loosen the bolt for the camshaft adjuster using the (T40080).





- Compress the chain tensioner - arrow A - and secure it using the (T10115) -arrow B-.
- Remove the bolt for the camshaft adjuster and remove it with the chain.

Installing

• Camshafts are secured using the (T10252).





- Place the chain onto the camshaft adjuster.





- Hold the camshaft adjuster in front of the exhaust camshaft so that notch - A - and pin - B - align.





- Place the chain in this position onto the intake camshaft chain sprocket, first at the top - arrow -.





- Slowly turn the intake camshaft using the (T10020) in the - direction of arrow A - until the camshaft adjuster fits onto the camshaft.

Note:
• If the pin does not fit into the notch: Remove the chain and place the chain on again.

- Tighten the new camshaft adjuster bolt. To do so, use the (T40080).





- Remove the (T10115) - arrow B -.



The rest of the assembly is basically a reverse of the removal sequence.

- Install the high pressure pump. Refer to --> [ High Pressure Pump ] High Pressure Pump.
- Note the tightening sequence for the cylinder head cover. Refer to --> [ Cylinder Head Cover ] Service and Repair.