Camshaft Timing Chains, Removing From Camshafts

Camshaft Timing Chains, Removing from Camshafts

Special tools, testers and auxiliary items required

• Spanner Wrench (3212)

• Multipoint Socket (T10035)

• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/2)

• Socket (T40058)

• Locking Pin (T40069)

• Locking Pin (T40071) , quantity: 2

• Oil Collecting and Extracting Device (V.A.G 1782)

• Camshaft Clamp (T40133) , quantity: 2

Removing

• The camshaft timing chains remain on the engine in the following description.

• If working on just one of the cylinder heads, it is not necessary to remove the timing chain cover on the opposite cylinder head.

- Remove the timing chain guard. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Install the cylinder head: left refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Remove the ribbed belt from the tensioning element and release the tension on the tensioning element:

• => [ Ribbed Belt, Vehicles with Hydraulic Power Steering ] Ribbed Belt, Vehicles With Hydraulic Power Steering

• => [ Ribbed Belt, Vehicles with Electro-Mechanical Power Steering ] Ribbed Belt, Vehicles With Electro-Mechanical Power Steering

- Place the (V.A.G 1782) under the engine.






- Remove the bolts - arrows - and move oil cooler to the side with the coolant hoses - 1 and 2 - still connected.








Refrigerant can cause serious personal injury.

• Do not open the air conditioning refrigerant circuit.

- Remove Air Conditioning (A/C) compressor bolts - arrows -.

Danger of damaging the refrigerant lines and hoses.

• Do not stretch, kink or bend refrigerant lines and hoses.

- Remove the A/C compressor from the bracket and with the lines still connected to the left longitudinal member, tie it up.

• Ignore - 1 -.

- Insert the (T40058) guide pins as follows:






• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the adapter.

- Remove the front noise insulation - 1 -.





- Rotate the crankshaft in the direction of engine rotation - arrow - to "TDC" using the (T40058) and wrench.






• The threaded holes - arrows - in the camshafts must face upward.






- Install the (T40133) in both cylinder heads and tighten - arrows - to 25 Nm.






• The illustration shows the left cylinder head.

- Remove the locking bolt - arrow - for the Top Dead Center (TDC) marking crankshaft from the cylinder block.






- Install the (T40069) in the hole and tighten to 20 Nm. Turn the crankshaft - 1 - back slightly to completely center the bolt, if necessary.






• The chain tensioner for the camshaft timing chain is oil-dampened. Compress it by slowly applying constant pressure.






- 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).

- 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 camshafts can get damaged.

• Do not use the (T40133) to counter hold when loosening the camshaft adjuster bolt or the camshaft sprocket.

- To counter hold at the affected camshaft adjuster, position the (T10172) with pins (T10172/2) and loosen the bolts using the socket (T10035).

• Ignore - 1 - and - arrow -.

- To counter hold, place the (3212) on the camshaft chain sprocket and loosen the bolt using the (T10035).






• Ignore - 1 - and - arrow -.

- Mark the installation position of the camshaft adjuster and the camshaft chain sprocket in color for installing later.






Danger of causing damage to the engine.

• 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 the bolts - 1 and 2 - on the left side of the cylinder cover, then remove the camshaft adjuster and the camshaft chain sprocket.

- Mark the installation position of the camshaft adjuster and the camshaft chain sprocket in color for installing later.






- Remove the bolts - 1 and 2 - on the right side of the cylinder cover, then remove the camshaft adjuster and the camshaft chain sprocket.

Installing

• Tightening specifications, refer to => [ Camshaft Timing Chains Overview ] Camshaft Timing Chains Overview.

• Replace any bolts that were tightened with an additional turn.

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 crankshaft - 1 - in TDC position using (T40069).

• Secure the camshafts in the TDC position on both cylinder heads using the (T40133) - arrows - (25 Nm).






• The illustration shows the left cylinder head.








The engine could be damaged.

• The camshaft chain sprockets must only be installed according to the following work steps:

• Install the camshaft chain sprockets according to the marks applied during removal.

• When mounting the camshaft chain sprockets, make sure that the pins on the camshaft chain sprockets engage in the holes on the camshafts - arrows -.

• Turn the camshaft chain sprocket on the camshaft counterclockwise until it stops - arrow -.






• The marking point - 1 - must align with the adjustment window - 2 -.













The engine could be damaged.

• The camshaft adjuster must only be installed according to the following work steps:

• Install the camshaft adjuster according to the marks applied during removal.

• The groove - 1 - in the camshaft adjuster must align with the adjustment window - 2 -.

- Mount the left camshaft timing chain onto the drive chain sprocket, install the camshaft adjuster and camshaft chain sprocket and install the bolts - 1 and 2 - loosely.






• The camshaft adjuster and the camshaft chain sprocket 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.






- Mount the right camshaft timing chain onto the drive chain sprocket, install the camshaft adjuster and camshaft chain sprocket and install the bolts - 1 and 2 - loosely.

• The camshaft adjuster and the camshaft chain sprocket must be able to still be rotated on camshaft and must not tip.

- Remove the (T40071).

- Mount the (3212) onto the camshaft chain sprocket for the right exhaust camshaft.






- Have a second technician hold the camshaft timing chain tensioned by pressing the camshaft chain sprocket in the direction of the - arrow -.

- Tighten the bolts as follows while the camshaft chain sprocket is still held under tension.






- Position the (T10172) with the pins (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.






- Tighten the camshaft adjuster bolts and the camshaft chain sprocket on the left cylinder head as follows:











- Tighten the camshaft adjuster bolts and the camshaft chain sprocket on the right cylinder head as follows:











- Remove the (T40133) on both cylinder heads - arrows -.






• The illustration shows the left cylinder head.

- Remove the (T40069).






- Using the (T40058) and a closed wrench, 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 - 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 crankshaft holder.

Install in reverse order of removal paying attention to the following:

- Install the locking bolt "TDC" mark crankshaft. Refer to => [ Marking Locking Bolt - Tightening Specification ] Service and Repair.

- Install A/C compressor.

- Install the oil cooler. Refer to => [ Engine Oil Cooler ] Engine Oil Cooler.

- Install the noise insulation.

- Installing the ribbed belt:

• => [ Ribbed Belt, Vehicles with Hydraulic Power Steering ] Ribbed Belt, Vehicles With Hydraulic Power Steering

• => [ Ribbed Belt, Vehicles with Electro-Mechanical Power Steering ] Ribbed Belt, Vehicles With Electro-Mechanical Power Steering

- Install the cylinder head covers. For the left side, refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover and for the right side, refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Install the left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.