Camshaft Timing Chain

Special tools and workshop equipment required

Torque Wrench 5-50 Nm V.A.G 1331
Open Ring Spanner Insert, AF 24 mm V.A.G 1332/9
Crankshaft Adapter T03003
Locking Pins T03006
Locking Pin T40069 Camshaft Clamp T40070
Key T40079

Removing

Fig 1: Identifying Front Noise Insulation -1 And 2-

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-- Remove the noise insulation -1 and 2-. Refer to Removal and Installation .

-- Remove the brake booster vacuum pump. Refer to Removal and Installation .

-- Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Remove timing chain guard upper section. Refer to UPPER TIMING CHAIN COVER .

-- Turn the crankshaft in the direction of engine rotation -arrow- to "TDC" using the T03003.

Fig 2: Turning Crankshaft To TDC

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The notch -1- in the T03003 is positioned vertically to the oil pan gasket.
The marking -2- on the vibration damper is positioned opposite the marking -3- on the sealing flange.

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

Fig 3: Locating Camshaft Threaded Holes
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NOTE:

If the threaded holes are not facing upward, turn the crankshaft 360°.

-- Install the T40070 on the cylinder head and tighten the bolts -arrows- to 25 Nm.

Fig 4: Identifying Camshaft Clamp T40070

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The T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

-- Remove the locking bolt -arrow- for the "TDC" marking from the cylinder block.

Fig 5: Identifying "TDC" Locking Bolt -Marking-, Tightening Specification

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-- Install the T40069 in the nut and tighten to 15 Nm. If necessary, move the crankshaft back and forth slightly to center the bolt.

Fig 6: Identifying Locking Pin T40069

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-- Push the chain tensioner glide track for the camshaft timing chain inward all the way with a screwdriver and lock the chain tensioner with the T03006.

Fig 7: Pushing Chain Tensioner Glide Track

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CAUTION:

If the running direction is reversed on a used camshaft timing chain, it could be destroyed.

Paint arrows to mark the timing chain running direction so it can be installed again. Do not mark camshaft timing chain with punch, notch or something similar.

The engine could be destroyed.

To prevent small parts from accidentally entering the engine through the opening in the timing chain compartment, seal the opening with a clean cloth.

-- Remove the bolts -1 and 2-, and remove both camshaft adjusters.

Fig 8: Locating Camshaft Adjusters

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-- Remove the camshaft timing chain from the drive wheel -arrow- for the camshaft timing chain.

Fig 9: Locating Drive Wheel

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Installing

For the correct tightening specifications, refer to CAMSHAFT TIMING CHAIN OVERVIEW .

NOTE:

Replace bolts that are tightened to the specification.

CAUTION:

Risk of damaging valves and piston crowns.

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

Drive chain for timing mechanism installed. Refer to TIMING MECHANISM DRIVE CHAIN .

Fig 10: Identifying Locking Pin T40069
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Secure crankshaft using T40069.
Install and tighten the T40070 to 25 Nm -arrows-.

Fig 11: Identifying Camshaft Clamp T40070
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-- Install camshaft timing chain on the output wheel -arrow- for the camshaft timing chain.

Fig 12: Locating Drive Wheel

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-- Re-install the camshaft adjuster according to the markings, refer to item 4 in Figure and item 9 in Figure.

Fig 13: Locating Camshaft Adjusters

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-- Position the camshaft adjuster and the camshaft timing chain, then loosely install the bolts -1 and 2-.

Both camshaft adjusters must be able to still be rotated on the camshaft and must not tip.

-- Remove T03006.

NOTE:

A second technician is needed for further work.

Fig 14: Identifying Tightening Camshaft Adjuster

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-- Position the T40079 on the camshaft adjuster for the exhaust camshaft.

-- Place the V.A.G 1331 with the V.A.G 1332/9 on the T40079.

-- Have a second technician pretension the camshaft adjuster clockwise to 25 Nm -arrow- and hold the tension.

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

Stage	Bolt	Tightening Specifications
1.	-1-	to the intake camshaft 60 Nm
1.	-2-	to the exhaust camshaft 60 Nm

-- Remove the T40079.

-- Remove the T40070 -arrows-.

Fig 15: Identifying Camshaft Clamp T40070

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-- Tighten the camshaft adjuster bolts as follows:

Fig 16: Locating Camshaft Adjusters

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Stage	Bolt	Additional Turn
2.	-1-	90°
2.	-2-	90°

-- Remove the T40069.

Fig 17: Identifying Locking Pin T40069

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-- Using the T03003, turn the crankshaft two turns in the direction of engine rotation -arrow- until it is back at "TDC".

Fig 18: Turning Crankshaft To TDC

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The notch -1- in the T03003 is positioned vertically to the oil pan gasket.
The marking -2- on the vibration damper is positioned opposite the marking -3- on the sealing flange.

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 19: Locating Camshaft Threaded Holes
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NOTE:

If the threaded holes are not facing upward, turn the crankshaft 360°.

-- Install the T40070 and tighten the bolts -arrows- to 25 Nm.

Fig 20: Identifying Camshaft Clamp T40070

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The T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

-- Install the T40069 in the nut and tighten to 15 Nm.

Fig 21: Identifying Locking Pin T40069

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The T40069 must engage in the locating groove of the crankshaft, otherwise repeat the adjustment.

-- Remove the camshaft locating tool.

-- Remove the crankshaft holder.

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

-- Tighten the "TDC" marking locking bolt. Refer to Fig 22.

Fig 22: Identifying "TDC" Locking Bolt -Marking-, Tightening Specification

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-- Install timing chain guard upper section. Refer to UPPER TIMING CHAIN COVER .

-- Install cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Install the brake booster vacuum pump. Refer to Removal and Installation .

-- Install the noise insulation. Refer to Removal and Installation .