Camshaft Timing Chain (with new tools)

Camshaft Timing Chain (with new tools)

Special tools, testers and auxiliary items required

• Assembly Tool (T10352)

• Counter Hold Tool (T10355)

• Locking Pin (T40011)

• Lever (T40243)

• Locking Tool (T40267)

• Camshaft Locator (T40271)

Removing

- Remove the upper timing chain cover. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.

- Rotate the vibration damper using the counter hold tool (T10355) into the Top Dead Center (TDC) position - arrow -.






• The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.

• The marks - 1 - on the camshafts must point upward.

- Remove the vibration damper. Refer to => [ Vibration Damper ] Service and Repair.

- Install the vibration damper bolt again with the thrust piece (T10368) and tighten it hand tight.






- Remove the lower timing chain cover. Refer to the following:

Passat and CC, refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

- Remove the control valve in the - direction of arrow - using the assembly tool (T10352).






The control valve has a left hand threads.

- Remove the bolts - arrows - and remove the bearing bracket.






- Press the oil pump chain tensioner in the - direction of the arrow - and secure it using a locking pin (T40011).






- Remove the oil pump chain tensioner guide pin - 1 -.

- Remove the oil pump chain tensioner.

- Remove the bolts - arrows -.






2 different chain tensioners may be installed.






Version 1:

- Install the lever (T40243) - arrows -.

- Lift up the locking wedge for the chain tensioner - arrow 1 -. Sand the end of the locking pin (T40011) down to a point. A screwdriver with a head approximately 1.5 mm wide can also be used.

There is a risk of damaging the chain tensioner. Proceed very carefully.

- Slowly press and hold the lever (T40243) in the - direction of arrow 2 -.

- Secure the chain tensioner using the locking pin (T40011).






Version 2:






- Install the lever (T40243) - arrows -.

- Press the chain tensioner lock ring - 1 - together and hold it.

- Slowly press and hold the lever (T40243) in the - direction of the arrow -.

- Secure the chain tensioner using the locking tool (T40267).






Continuation for All

- Remove the lever (T40243).

- Bolt the camshaft locating tool (T40271/2) to the cylinder head and push the tool into the sprocket splines in the - direction of arrow 2 -. If necessary, slightly rotate the intake camshaft in the - direction of arrow 1 - using a wrench.






- Bolt the camshaft locating tool (T40271/1) to the cylinder head. Hold the camshaft with a wrench in a clockwise direction - arrow -.






- Remove the guide pin - A - and remove the tensioning rail while continuing to hold the camshaft.

- Slide the camshaft locating tool (T40271/1) into the splines for the sprocket in the - direction of arrow 2 -. If necessary, turn the exhaust camshaft clockwise in the - direction of arrow 1 - further, until the camshaft locating tool can be pushed in. The camshaft timing chain must be loose between the sprockets.






- Remove the guide rail guide pins - A - and the guide rail.






- Remove the timing chain.

Installing

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

• The help of a second mechanic is needed to install the timing chain.

• The painted links of the timing chain must be positioned on the marks on the sprockets.






- Mount the timing chain on the intake camshaft.

- Mount the timing chain on the exhaust camshaft.

- Lay the timing chain on the crankshaft and hold it there.

- Install the camshaft timing chain guide rail and tighten the guide pins - A -.






• Use the help of a second mechanic to hold the exhaust camshaft in place.

- Slowly rotate the exhaust camshaft in the - direction of arrow 1 - until the camshaft locating tool (T40271/1) can be pushed out of the sprocket splines.






- Carefully release the camshaft, until the camshaft timing chain is laying on the upper guide rail. Hold the camshaft in this position.

Always check before installing the tensioning rail, whether the colored chain link is still aligned to the mark on the camshaft!

- Continue to hold the camshaft and install the camshaft timing chain tensioning rail. Tighten guide pin - A -.






- Remove the camshaft locating tool (T40271/1).

- Push the camshaft locating tool (T40271/2) out of the sprocket splines in the - direction of arrow 2 -, If necessary, slightly rotate the intake camshaft in the - direction of arrow 1 - using a wrench.






- Remove the camshaft locating tool (T40271/2).

- Remove the locking pin (T40011) or the locking tool (T40267) , depending on the version.

- Check that the position of the colored chain links are aligned with the marks on the sprockets.






- Install the drive chain for the oil pump and the chain tensioner. Tighten the guide pin - 1 - and remove the locking pin (T40011).






- Install the bolts - arrows - and tighten them.






- Carefully install the bearing mount. Do not tilt it when doing this. Hand tighten the bolts - arrows -






- Tighten the bolts - arrows - to specifications, refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.

- Install the control valve, see - item 6 - in the => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.

• Due to the ratio, the painted chain links no longer match up after the engine has been turned. For this reason, the valve timing must be checked again with the gauge.

- Rotate the crankshaft 2 revolutions in engine rotation direction and check the valve timing. Refer to => [ Valve Timing, Checking ] Adjustments.

Further installation is in the reverse order of removal.