Camshaft Timing Chain, Removing From Camshafts: Installing

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Tightening specifications. Refer to OVERVIEW - CAMSHAFT TIMING CHAINS .

NOTE:

Replace the bolts that were tightened with an additional turn.

CAUTION:

Risk of damaging valves and piston crowns.

If camshafts are rotated, crankshaft may not rest with any piston at "TDC".

The timing mechanism drive chain is installed. Refer to TIMING MECHANISM DRIVE CHAIN, REMOVING AND INSTALLING .

Fig 1: Crankshaft Locking Pin T40069
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Crankshaft -1- secured in "TDC" using Crankshaft Locking Pin T40069.

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

Fig 2: Camshaft Adjuster T40133
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NOTE:

The illustration shows the left cylinder head.

Fig 3: Identifying Camshaft Sprocket Pins And Holes On Camshafts

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CAUTION:

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-.

Fig 4: Turning Camshaft Chain Sprocket
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The marking point -1- must align with the adjustment window -2-.

Fig 5: Aligning Marking Point With Adjustment Window
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Fig 6: Aligning Camshaft Adjuster Groove With Adjustment Window

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CAUTION:

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.

Fig 7: Identifying Cylinder Cover Bolts -1 And 2-

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

-- Remove the Locking Pin T40071.

-- Install the camshaft adjuster on the right cylinder head according to the markings applied during removal.

Fig 8: Identifying Right Camshaft Adjuster And Camshaft Sprocket Bolts

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-- 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 Locking Pin T40071.

-- Mount the Wrench - Pin Type 3212 onto the camshaft chain sprocket for the right exhaust camshaft.

Fig 9: Counterhold Exhaust Camshaft With 3212

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

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

Step	Bolt	Tightening Specification
1.		to the exhaust camshaft 80 Nm
1.	-1-	to the intake camshaft 80 Nm

For Camshaft Adjusters with Three Notches

Fig 10: Counterholding Affected Camshaft Adjuster (Camshaft Adjusters With Three Notches)

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-- Position the Wrench - Camshaft T40269 on the camshaft adjuster for the left intake camshaft.

-- Position the Torque Wrench 1332 40-200Nm VAG1332 with the Torque Wrench 1332 Insert - Open Ring Wrench - 24mm VAG1332/9 on the Wrench - Camshaft T40269.

-- Have a second technician hold the camshaft timing chain tensioned to approximately 40 Nm by pressing the Torque Wrench 1332 40-200Nm VAG1332 in direction of -arrow-.

For Camshaft Adjusters with Four Notches

Fig 11: Counterholding Affected Camshaft Adjuster (Camshaft Adjusters With Four Notches)

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-- Position the Camshaft Adjuster Key T40079 on the camshaft adjuster for the left intake camshaft.

-- Position the Torque Wrench 1332 40-200Nm VAG1332 with the Torque Wrench 1332 Insert - Open Ring Wrench - 24mm VAG1332/9 on the Camshaft Adjuster Key T40079.

-- Have a second technician hold the camshaft timing chain tensioned to approximately 40 Nm by pressing the Torque Wrench 1332 40-200Nm VAG1332 in direction of -arrow-.

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

Continuation for All

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

Step	Bolt	Tightening Specification
1.	-1-	To the exhaust camshaft 80 Nm
1.		To the intake camshaft 80 Nm

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

Fig 12: Identifying Cylinder Cover Bolts -1 And 2-

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Step	Bolt	Tightening Specification
2.	-1-	To the exhaust camshaft final tightening specification Refer to -item 2- Bolt (See Figure)
2.	-2-	To the intake camshaft final tightening specification Refer to -item 1- Bolt (See Figure)

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

Fig 13: Identifying Right Camshaft Adjuster And Camshaft Sprocket Bolts

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Step	Bolt	Tightening Specification
2.	-1-	To the intake camshaft final tightening specification Refer to -item 3- Bolt (See Figure)
2.	-2-	To the exhaust camshaft final tightening specification Refer to -item 1- Bolt (See Figure)

-- Remove the Camshaft Clamp T40133 on both cylinder heads -arrows-.

Fig 14: Camshaft Adjuster T40133

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NOTE:

The illustration shows the left cylinder head.

-- Remove the Crankshaft Locking Pin T40069.

Fig 15: Crankshaft Locking Pin T40069

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-- Using the Crankshaft Socket T40058 and a ring wrench, turn the crankshaft two turns in the direction of engine rotation -arrow- until it is back at "TDC".

Fig 16: Counter Hold Crankshaft Using Socket T40058

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NOTE:

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.

Fig 17: Camshafts
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-- Install the Camshaft Clamp T40133 in both cylinder heads and tighten -arrows- to 25 Nm.

Fig 18: Camshaft Adjuster T40133

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-- Install the Crankshaft Locking Pin T40069 directly in the hole.

Fig 19: Crankshaft Locking Pin T40069

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The Crankshaft Locking Pin T40069 must engage in the locating hole in 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. Note the following:

-- Install the locking bolt "TDC" mark crankshaft. Refer to Fig 20.

Fig 20: Identifying Locking Bolt

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-- Install the Air Conditioning (A/C) compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING .

-- Install the engine oil cooler. Refer to ENGINE OIL COOLER, REMOVING AND INSTALLING .

-- Install the noise insulations. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Installing the ribbed belt:

-- Install the cylinder head covers. Refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING , RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install the left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .