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
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Camshaft Clamp (T40133) , quantity: 2
Removing
Risk of injury from coolant fan starting by itself.
• The radiator fan can come on even when the ignition is turned off, for example, caused by the heat still in the engine compartment.
• 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.
- 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 noise insulation - 1 and 2 -.
- Remove the ribbed belt from the tensioning element. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Place the (V.A.G 1782) under the engine.
- Remove the bolts - arrows - and lay aside the oil cooler with the coolant hoses - 1 and 2 - 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.
• Small diameter - arrow 2 - points to adapter.
- Rotate the crankshaft in the direction of engine rotation - arrow - to Top Dead Center (TDC) using the (T40058) and an offset box 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 TDC marking crankshaft from the cylinder block.
- Install the (T40069) in the hole and tighten to 20 Nm. Turn the crankshaft - 1 - back and 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 counterhold when loosening the camshaft adjuster bolt or the camshaft sprocket.
- To counter hold at the affected camshaft adjuster, position the (T10172) with (T10172/2) and loosen the bolts using the (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 reinstalling 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 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 reinstalling 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 bolts which have been tightened to an additional torque.
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 the (T40069).
• Secure the camshafts in the TDC position on both cylinder heads using the (T40133) - arrows - (25 Nm).
• The cylinder head for cylinder bank 2 (left) is shown in the illustration.
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 (T10172/2) on the left intake camshaft adjuster.
- Have a second technician hold the camshaft timing chain tensioned by pressing the counterhold 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 cylinder head for cylinder bank 2 (left) is shown in the illustration.
- Remove the (T40069).
- Using the (T40058) and an offset box 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.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install the locking bolt TDC mark crankshaft. Refer to => [ Top Dead Center (TDC) Marking Locking Bolt - Tightening Specification ] Service and Repair.
- Install A/C compressor.
- Install the oil cooler. Refer to => [ Engine Oil Cooler ] Service and Repair.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the noise insulation.
- Install the cylinder head covers. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover and for the => [ 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.