Camshaft Timing Chain
Camshaft Timing Chain
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 )
• Wrench (T40049)
• Drill bit 3.3 mm dia. (2x)
Removing
- 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.
- Disconnect engine and transmission. Refer to: Vehicles with manual transmission => [ Engine and Transmission, Separating ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine and Transmission, Separating ] Engine, Automatic Transmission, Removing and Installing.
- Leave engine on the Scissor Lift Table (VAS 6131 A) or secure the engine to the engine and transmission holder. Refer to: Vehicles with manual transmission => [ Engine, Securing to Engine and Transmission Holder ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Securing to Engine and Transmission Holder ] Engine, Automatic Transmission, Removing and Installing.
- Remove covers for timing chains. Refer to => [ Timing Chain Covers ] Timing Chain Covers.
- Install key (T40049) at rear on crankshaft e.g. using 2 old bolts for dual-mass flywheel.
- 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 the 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 -.
- Mark running direction of left timing chain with paint.
- Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket (T10035).
- Remove camshaft chain sprocket, camshaft adjuster and timing chain.
- 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 -.
- Mark running direction of right timing chain with paint.
- Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket (T10035).
- Remove camshaft chain sprocket, camshaft adjuster and timing chain.
Installing
• Secure crankshaft in TDC position using crankshaft holder (3242).
• Drive chain for timing mechanism installed. Refer to => [ Timing Mechanism Drive Chain ] Timing Mechanism Drive Chain.
• 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.
- 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).
- Using key (T40049), rotate crankshaft approximately 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.
- Using key (T40049), 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 (T40047) 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 (T40047) on bolt - 2 -.
- Tighten camshaft bolt - 1 - on intake camshaft to initial tightening specifications.
• Tightening Specifications: 40 Nm.
- Remove setting gauge (T40047).
- Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening specifications.
• Tightening Specifications: 40 Nm.
• Camshaft locators (T40046) 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 setting gauge (T40047) 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).
- Using key (T40049) 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 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).
- Screw 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.