Camshaft adjuster, removing and installing

Fig 1: Identifying Special Tools - Camshaft Adjuster, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required 

• Multi-point socket T40080
• Camshaft locator T10252
• Toothed Belt Tensioner T10020
• Locking Pin T10115

Removing 

• Remove high-pressure pump. → - 24 - MULTIPORT FUEL INJECTION (MFI)

Fig 2: Removing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows  -.
• Remove cylinder head cover → Cylinder head cover, removing and installing 
• Remove vacuum pump.

Fig 3: Removing Camshaft Adjuster Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove camshaft adjuster housing - arrows  -.

Fig 4: Bringing Marking On Camshaft Gear To Alignment With Marking On Toothed Belt Guard

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Bring marking on camshaft gear to alignment with marking on toothed belt guard. Recesses - arrows  - now point to each other vertically.

Fig 5: Identifying Camshafts Secured Using Camshaft Locator T10252

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install camshaft locator T10252 as shown and secure - arrows  -.
• Loosen mounting bolt from camshaft adjuster using socket insert T40080.

Fig 6: Compressing Chain Tensioner And Securing Using Locking Pin T10115

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Compress chain tensioner - arrow A  - and secure it using Locking Pin T10115 - arrow B  -.
• Remove mounting bolt from camshaft adjuster and remove it with chain.

Installing 

Fig 7: Identifying Camshafts Secured Using Camshaft Locator T10252

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The camshafts must be fixed in place with camshaft locating tool T10252.

• Place chain on to camshaft adjuster.

Fig 8: Identifying Camshaft Adjuster & Exhaust Camshaft Notch And Pin

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Hold camshaft adjuster in front of exhaust camshaft so that the notch - A  - and pin - B  - are positioned across from one another.

Fig 9: Identifying Intake Camshaft Chain Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place chain in this position on to chain sprocket of intake camshaft, first at top - arrow  -.

Fig 10: Turning Intake Camshaft Using Pin Wrench T10020 Until Camshaft Adjuster Fits On To Camshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slowly turn intake camshaft with Toothed Belt Tensioner T10020 in direction of - arrow A  - until camshaft adjuster fits onto camshaft.

• Tighten camshaft adjuster screw. To do so, use socket insert T40080.

Fig 11: Compressing Chain Tensioner And Securing Using Locking Pin T10115

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Locking Pin T10115 - arrow B  -.

The rest of assembly is basically a reverse of disassembling sequence.

• Install intake manifold → - 24 - MULTIPORT FUEL INJECTION (MFI)
• Install high pressure pump → - 24 - MULTIPORT FUEL INJECTION (MFI)
• Install vacuum pump → 47 - BRAKES - HYDRAULIC COMPONENTS .

Torque specifications 

Cylinder head, camshafts → Cylinder head, camshafts, overview 

Cylinder head, assembly overview → Cylinder head, assembly overview