Camshaft Timing Chains, Removing From Camshafts
Camshaft Timing Chains, Removing from Camshafts
Special tools, testers and auxiliary items required
• Torque Wrench 40-200 Nm (V.A.G 1332)
• Open Ring Spanner Insert, AF 24 mm (V.A.G 1332/9)
• Multipoint Socket (T10035)
• Counterhold Tool Touareg V10 (T10172)
• Adapter (T10172/2)
• Socket (T40058)
• Locking Pin (T40069)
• Oil Collecting and Extracting Device (V.A.G 1782)
• Locking Pin (T40071) , quantity: 2
• Camshaft Clamp (T40133) , quantity: 2
Removing
• The camshaft timing chains remain on the engine in the following description.
- Remove the respective cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Remove the left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Remove the noise insulation - 1 and 2 -..
Vehicles without the After-Run Coolant Pump (V51)
- Remove the bolt - 1 - and nut - 3 - and the lock carrier left brace - 2 -.
- Place the (V.A.G 1782) under the engine.
- Remove the bolts - arrows - and lay aside the oil cooler with the coolant hoses - 1 and 2 - connected.
Vehicles with the After-Run Coolant Pump (V51)
- Remove the after-run coolant pump. Refer to => [ After-Run Coolant Pump (V51) ] After-Run Coolant Pump (V51) and the oil cooler => [ Engine Oil Cooler ] Engine Oil Cooler.
All Vehicles
- Insert the (T40058) guide pins as follows:
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the adapter.
- Turn the crankshaft in the direction of engine rotation - arrow - to "TDC" using the (T40058).
- Remove the locking bolt - arrow - for the "TDC" marking from the cylinder block.
• The crankshaft locating hole is difficult to find when the engine is installed.
• Rotate the engine until the small notch - 1 - on the vibration damper aligns at the left of the housing separation point - 2 - between the cylinder block and the guide frame. This makes it easier to install the (T40069).
• The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the (T40069).
• The threaded holes - arrows - in the camshafts must face upward.
- Install the (T40069) in the hole and tighten to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.
- Install the (T40133) in both cylinder heads and tighten the bolts - arrows - to 25 Nm.
• The illustration shows the left cylinder head.
- Press the left camshaft timing chain tensioner guide rails in as far as the stop using a screwdriver - 1 - and secure the chain tensioner with a (T40071).
• The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.
- Press the right camshaft timing chain tensioner guide rails in as far as the stop using a screwdriver - 1 - and secure the chain tensioner with a (T40071).
• The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.
The camshaft could be damaged.
• Do not use the (T40133) to counterhold when loosening the camshaft adjuster bolts - 1 -.
- To counterhold at the affected camshaft adjuster, position the (T10172) with the (T10172/2) and loosen using the (T10035).
- Mark the installation position of the camshaft adjuster with paint for installation later.
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 the left cylinder head and remove both camshaft adjusters.
- Mark the installation position of the camshaft adjuster with paint for installation later.
- Remove the bolts - 1 and 2 - on the right cylinder head and remove both camshaft adjusters.
Installing
• For the correct tightening specifications, refer to => [ Camshaft Timing Chains Overview ] Camshaft Timing Chains Overview.
• Replace the bolts which are being tightened with an additional turn.
• Replace the O-ring for the Top Dead Center (TDC) marking locking bolt.
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 the crankshaft in the "TDC" position using (T40069).
• (T40133) mounted on both cylinder heads and fastened to 25 Nm - arrows -.
• The illustration shows the left cylinder head.
The engine could be damaged.
• For the following steps, only install the camshaft adjuster so the grooves - 1 and 4 - are aligned with the windows (beveled surfaces) - 2 and 3 -.
• Reinstall camshaft adjuster on the left cylinder head according to the mark applied during removal.
- Position the left camshaft timing chain on the drive sprocket and the camshaft adjuster and loosely install bolts - 1 and 2 -.
• Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.
- Remove the (T40071).
• Reinstall camshaft adjuster on the right cylinder head according to the mark applied during removal.
- Position the right camshaft timing chain on the drive sprocket and the camshaft adjuster and loosely install bolts - 1 and 2 -.
• Both camshaft adjusters must be able to still be rotated on the camshaft and must not tip.
- Remove the (T40071).
- Position the (T10172) with the (T10172/2) on the left intake camshaft adjuster.
- Have a second technician hold the camshaft timing chain tensioned by pressing the counter hold tool in the direction of the - arrow -.
- Tighten the bolts as follows while the camshaft adjuster is still held under tension.
- Position the (T10172) with the (T10172/2) on the right exhaust camshaft adjuster.
- Have a second technician hold the camshaft timing chain tensioned by pressing the counter hold tool in the direction of the - arrow -.
- Tighten the bolts as follows while the camshaft adjuster is still held under tension.
- Remove the (T40133) on both cylinder heads - arrows -.
• The illustration shows the left cylinder head.
- Tighten the camshaft adjuster bolts on the left cylinder head as follows:
- Tighten the camshaft adjuster bolts on the right cylinder head as follows:
- Remove the (T40069).
- Using the (T40058) , turn the crankshaft two turns in the direction of engine rotation - arrow - until it is back at "TDC".
• If it is accidentally rotated beyond "TDC", rotate it back approximately 30° and set it to "TDC" again.
• The threaded holes - arrows - in the camshafts must face upward.
- Install the (T40133) in both cylinder heads and tighten the bolts - arrows - to 25 Nm.
- Install the (T40069) directly in the hole.
• The (T40069) must engage in the locating hole of the crankshaft - 1 -, otherwise repeat the adjustment.
- Remove the camshaft locating pins on both cylinder heads.
- Remove the (T40069).
Install in reverse order of removal paying attention to the following:
- Install the "TDC" marking locking bolt. Refer to => [ Marking Locking Bolt - Tightening Specification ] Service and Repair.
- Install the left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Install the cylinder head covers. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install the oil cooler. Refer to => [ Engine Oil Cooler ] Engine Oil Cooler.
- Install after-run coolant pump (V51). Refer to => [ After-Run Coolant Pump (V51) ] After-Run Coolant Pump (V51).
- Install the lock carrier brace.
- Install the noise insulation..