Camshaft Gear/Sprocket: Service and Repair
Camshaft Compensation Wheel and Input Gear
• After each separation of the gear drive, the position of the pump pistons in the pump injector units must be checked after completing assembly and adjusted if necessary. Refer to --> [ Pump Injector Unit Pump Piston, Checking Position and Adjusting ] Pump Injector Unit Pump Piston, Checking Position and Adjusting.
Special tools, testers and auxiliary items required
• Torque wrench (5 to 50 Nm) (VAG 1331)
• Torque wrench (40 to 200 Nm) (VAG 1332)
• Puller (T10055)
• Multi point socket (T10198)
• Clamping device (T10199)
• Wrench (T10211)
• Work sequence described and components depicted here apply to cylinder bank 1. The difference for cylinder bank 2 is minimal and is not described separately for this reason.
Removing
- Remove engine and transmission. Refer to --> [ Engine, Removing ] Engine Removing.
- Remove intake manifold flap and crankcase ventilation line from respective cylinder.
- Remove acoustic cover and cylinder head cover of the applicable cylinder head.
- Check rocker arm shaft running surfaces for wear.
- Remove coolant pipe below tandem and fuel pump.
- Remove vibration damper --> [ (Item 4) Vibration damper ] Service and Repair. For this, use counter holder (T10172) with threading pins (T10172/1).
- Install camshaft tool (T10195) onto crankshaft stub. Observe alignment pin while doing so.
- Now carefully rotate crankshaft until the pin for the camshaft tool (T10195) is inserted into alignment bore.
- Remove the corresponding pump, refer to --> [ Tandem and Fuel Pump ] Tandem and Fuel Pump.
• Cylinder bank 1: Tandem pump
• Cylinder bank 2: Fuel Pump (FP)
- Remove oil supply line to exhaust turbocharger.
- Position wrench (T10211) as shown and loosen adapter ring on pump injection unit central connector.
- Remove Camshaft Position (CMP) sensor (G40) - C - (only on cylinder bank 1).
- Remove outer bearing cap - A -, place clamping device (T10199) on camshaft gear and tighten its bolt to 40 Nm.
- Loosen bolt - B - for camshaft gear using socket insert (T10198) and remove together with tandem pump drive.
- Loosen bolts on clamping device (T10199) and remove it.
- Remove the compensating piston - B - for full-floating axle of compensation linkage.
- Remove pull-off head for pump injector unit from puller (T10055).
- Install the puller (T10055) into full-floating axle as shown and pull full-floating axle out of its seat in - direction of arrow -, using careful knocking motions.
- Now pull out the outer compensation linkage on transmission side, including its sleeve. If necessary, loosen by hitting lightly with a plastic hammer.
- Remove camshaft gear.
- Now remove compensation wheel and inner compensation linkage on engine side.
- Remove diamond disc from camshaft stub.
Installing
- Clean bearing cap contact surfaces of any sealant residue.
- Oil compensation linkage sleeve guide surfaces.
• If there is marked crimping or deposits on compensation linkage sleeve guide surfaces, these must be replaced.
- First engage inner, engine-side compensation linkage - A - at bottom (if necessary, guide through compensating piston hole with finger) and then slide top onto sleeve.
- Place a new diamond disc on camshaft stub.
- Bring lower, transmission-side compensation linkage into position --> [ Compensation linkage position ] and insert compensation wheel with phase - arrow - in direction of transmission.
- When inserting, turn the camshaft gear so marking - arrow - on sensor wheel aligns with upper edge of sealing surface.
- Secure construction by carefully sliding full-floating axle on by hand with force as even as possible.
CAUTION!
There is the risk that a linkage may pivot to the side out of the wheel cassette and will not engage when full-floating axle is inserted, or it may be distorted when inserting the full-floating axle.
- Insert guide sleeve in transmission-side compensation linkage.
- Carefully pull full-floating axle back out of its seat. When doing so, ensure compensation linkages which have already been positioned remain in correct location.
- Install transmission-side compensation linkage with writing toward transmission. When doing so, support if necessary with light tapping on guide sleeve with a plastic hammer.
- Control correct seating of compensation linkage with finger through compensating piston hole.
- Compensation wheel must be aligned so that the holes in the four linkages and in sprocket are positioned flush behind one another --> [ Compensation linkage position ]
Compensation linkage position
- Lubricate free-floating axle with oil, then carefully slide in by hand and with as even a force as possible. Correct seat of full-floating axle faces toward a clear gap to cylinder head bore - arrow -.
- Remove tandem or fuel pump drive.
- Position bearing cap flush with cylinder head edge using Sealant (AMV 176 501) and tighten. Tightening specifications, .
- Install new compensating pistons. Tightening specifications, refer to.
- Positing clamping device (T10199) and tighten camshaft gear bolt.
Tightening Specifications
