Chain 2
Camshaft Timing Chains
Special tools, testers and auxiliary items required
• Crankshaft Holder (3242)
• Torque Wrench 40-200 Nm (V.A.G 1332)
• Open Ring Spanner Insert, AF 24 mm (V.A.G 1332/9)
• Camshaft Clamp (T40070) , quantity: 2
• Locking Pin (T40071) , quantity: 2
• Key (T40079)
• Adapter (T40257)
• Wrench (T40263)
Removing
• The camshaft timing chains stay 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 respective timing chain cover. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover, => [ Right Timing Chain Cover ] Right Timing Chain Cover.
- Attach the (T40257) to the (T40263).
- Mount the adapter over the bolts on the vibration damper and turn the crankshaft in direction of engine rotation - arrow - to "TDC".
• The threaded holes - arrows - in the camshafts must face upward.
- (T40070) mounted on both cylinder heads and tightened to 25 Nm - arrows -.
• The (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
- Remove the drain plug - arrow - from the upper section of the oil pan by using a long hex socket wrench with ball head.
- Install the (3242) in the hole and tighten to 20 Nm. Turn the crankshaft - 1 - back and slightly to completely center the bolt, if necessary.
- 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.
- 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 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 bolts that are tightened to the specification.
• Replace the locking bolt seal for the "TDC" marking.
Risk of damaging valves and piston crowns.
• If the 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 crankshaft - 1 - in "TDC" position using (3242).
• (T40070) mounted on both cylinder heads and tightened to 25 Nm - arrows -.
- Install the camshaft adjuster on the left cylinder head according to the markings applied during removal.
- Position the 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).
- Install the camshaft adjuster on the right cylinder head according to the markings applied during removal.
- Position the 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).
- Place the (T40079) on the intake camshaft adjuster on the left cylinder head.
- Place the (V.A.G 1332) with (V.A.G 1332/9) on the (T40079).
- Have a second technician tension the camshaft adjuster in the direction of the - arrow - to 40 Nm.
- Tighten the bolts as follows while the camshaft adjuster is still held under tension.
- Position the (T40079) on the exhaust camshaft adjuster on the right cylinder head.
- Place the (V.A.G 1332) with (V.A.G 1332/9) on the (T40079).
- Have a second technician tension the camshaft adjuster in the direction of the - arrow - to 40 Nm.
- Tighten the bolts as follows while the camshaft adjuster is still held under tension.
- Remove the (T40079).
- Remove the (T40070) on both cylinder heads - arrows -.
- 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 (3242).
- Turn the crankshaft 2 turn in direction of engine rotation - arrow - until the crankshaft is at "TDC" again.
• 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.
- (T40070) mounted on both cylinder heads and tightened to 25 Nm - arrows -.
• The (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
- Install the (3242) in the hole and tighten to 20 Nm.
• The (3242) 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 (3242).
- Install the sealing plug - arrow - for the "TDC" marking in the upper oil pan. Refer to => [ Upper Oil Pan Overview ] Upper Oil Pan Overview.
Install in reverse order of removal paying attention to the following:
- Install the timing chain covers. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover, => [ Right Timing Chain Cover ] Right Timing Chain Cover.
- Install the cylinder head covers. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.