Camshaft Gear/Sprocket: Service and Repair

Camshaft Compensation Wheel and Gear

• After each separation of the gear drive, the position of the pump pistons in the pump injector units must be checked after completing the assembly and adjusted if necessary. Refer to => [ Pump Injector Unit Pump Piston Position, Checking and Adjusting ] Testing and Inspection.

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Puller (T10055)

• Socket XZN 16 (T10198)

• Clamping Device (T10199)

• Wrench (T10211)

• The procedure 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 the engine and transmission. Refer to => [ Engine, Removing ] Engine, Removing.

- Remove the intake manifold flap and crankcase ventilation line from the respective cylinder.

- Remove the acoustic cover and cylinder head cover from the applicable cylinder head.

- Check the rocker arm shaft running surfaces for wear.

- Remove the coolant pipe below the tandem and fuel pump.

- Remove the vibration damper => [ (Item 4) Vibration Damper ] Description and Operation. For this, use counterhold tool Touareg V10 (T10172) with pins (T10172/1).

- Install the camshaft tool (T10195) onto the crankshaft stub. Observe the alignment pin while doing so.






- Now, carefully rotate the crankshaft until the pin for the camshaft tool (T10195) is inserted into the 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

- Remove the oil supply line from the turbocharger.

- Position the wrench (T10211) as shown and loosen the adapter ring on the pump injection unit central connector.






- Remove the camshaft position sensor (G40) - C - (only on cylinder bank 1).






- Remove the outer bearing cap - A -, place the clamping device (T10199) on the camshaft gear and tighten its bolt to 40 Nm.

- Loosen the bolt - B - for the camshaft gear using the socket XZN 16 (T10198) and unscrew together with tandem pump drive.

- Loosen the bolts on the clamping device (T10199) and remove it.

- Remove the compensating piston - B - for the full-floating axle of the compensation linkage.






- Remove the pull-off head for the pump injector unit using the puller (T10055).

- Screw the puller (T10055) into full floating axle as shown and pull the full floating axle out of its seat in the - direction of arrow -, using careful knocking motions.






- Now, pull out the outer compensation linkage on the transmission side, including its sleeve. If necessary, loosen by hitting lightly with a plastic hammer.






- Remove the camshaft gear.

- Now, remove the compensation wheel and inner compensation linkage on the engine side.

- Remove the diamond disc from the camshaft stub.






Installing

- Clean the bearing cap contact surfaces of any sealant residue.

- Oil the compensation linkage sleeve guide surfaces.

• If there is marked crimping or deposits on the compensation linkage sleeve guide surfaces, these must be replaced.

- First, engage the inner, engine side compensation linkage - A - at the bottom (if necessary, guide through compensating piston hole with finger) and then slide the top onto the sleeve.






- Place a new diamond disc on the camshaft stub.

- Bring the lower, transmission side compensation linkage into position, refer to => [ Compensation Linkage Position ] and insert the compensation wheel with the phase - arrow - in the direction of the transmission.






- When inserting, turn the camshaft gear so the mark - arrow - on the sensor wheel aligns with the upper edge of the sealing surface.






- Secure the construction by carefully sliding the full floating axle on by hand with force as even as possible.


There is the risk that a linkage may pivot to the side out of the wheel cassette and will not engage when the full floating axle is inserted, or it may be distorted when inserting the full floating axle.

- Insert the guide sleeve in the transmission side compensation linkage.

- Carefully pull the full floating axle back out of its seat. When doing so, ensure the compensation linkages which have already been positioned remain in the correct location.

- Install the transmission side compensation linkage with the writing toward the transmission. When doing so, support if necessary with light tapping on the guide sleeve with a plastic hammer.

- Control the correct seating of the compensation linkage with your finger through the compensating piston hole.

- The compensation wheel must be aligned so that the holes in the four linkages and in the sprocket are positioned flush behind one another. Refer to => [ Compensation Linkage Position ].

Compensation Linkage Position





- Lubricate the free floating axle with oil, then carefully slide in by hand and with as even a force as possible. Correct seating of the full floating axle faces toward a clear gap to the cylinder head bore - arrow -.






- Remove the tandem or fuel pump drive.

- Position the bearing cap flush with the cylinder head edge using sealant (AMV 176 501) and tighten. Tightening specifications.

- Install new compensating pistons. Tightening specifications.

- Install the clamping device (T10199) and tighten the bolt for the camshaft gear to the 2nd pass.

- Check the position of the pump pistons inside the pump injector units and adjust if necessary. Refer to => [ Pump Injector Unit Pump Piston Position, Checking and Adjusting ] Testing and Inspection.

- Tighten the bolt for the camshaft gear to the 3rd pass.

Tightening Specifications