Camshaft Timing Chain, Removing From Camshaft: Removing

• Engine and transmission installed.

-- Drain the coolant. Refer to COOLANT, DRAINING .

-- Remove the pre-catalytic converter. Refer to EXHAUST SYSTEM COMPONENTS .

-- Remove the vacuum pump. Refer to OVERVIEW - VACUUM PUMP .

-- Remove rear right coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the left rear coolant pipe. Refer to LEFT REAR COOLANT PIPE, REMOVING AND INSTALLING [CATA] .

-- Remove the bolts -1 to 4- and the left timing chain guard.

Fig 1: Bolt Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -1 to 4- and the right timing chain guard.

Fig 2: Identifying Bolts -1 Through 4-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the Crankshaft Socket:T40058  guide pins as follows:

Fig 3: Guide Pin And Adapter T40058

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The large diameter -arrow 1- faces the engine.
• The small diameter -arrow 2- faces the adapter.

Fig 4: Identifying TDC With Special Tool Adapter T140058

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn the crankshaft to "TDC" using the Crankshaft Socket:T40058  .

NOTE:

The Camshaft Adjustment Pins:T40060  has a flat part -2- which makes it easier to insert if the holes on the camshaft and the cylinder head are slightly offset.

Fig 5: Identifying Adjustment Pin T40060

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Insert the pin so that the bolt -1- is perpendicular to the camshaft axle.

Move the bolt -1- 90° in direction of -arrow- so that it is perpendicular to the camshaft axle and it is possible to attain the correct "TDC" position.

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

Fig 6: Checking Camshafts TDC Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• It must be possible to secure the camshafts with the Camshaft Adjustment Pins:T40060  .
• The pin -arrow- in the Camshaft Adjustment Pins:T40060  must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

• The pin -arrow- in the Camshaft Adjustment Pins:T40060  must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).
  Fig 7: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

To collect escaping engine oil, place a clean cloth under the upper part of the oil pan.

Fig 8: Identifying Locking Bolt Of Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove locking bolt -arrow- from upper part of oil pan.

Fig 9: Identifying Crankshaft Holder 3242

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the Crankshaft Key:3242  in the hole and tighten to 20 Nm. Rotate the crankshaft back and forth slightly to center the pin completely, if necessary.

-- To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Fig 10: Identifying Chain Tensioner Secured Using 3.3 Mm Diameter Drill Bit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the tensioning track for the left camshaft timing chain tensioner in the direction of the -arrow- and secure the chain tensioner with a 3.3 mm drill bit -item 1-.

Fig 11: Identifying Bolts -1- For Guide Rail And Bolts -2- For Camshaft Chain Sprocket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -3- and remove the tensioning rail.

-- Remove the bolt -1- for the guide rail and -2- for the camshaft chain sprocket.

-- Remove the camshaft chain sprocket and guide rail.

-- To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Fig 12: Identifying 3.3 mm Diameter Drill Bit -1- To Install Chain Tensioner Guide Rail On Right Camshaft Timing Chain

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the chain tensioner guide rail for the right camshaft timing chain in the direction of the -arrow- and secure the chain tensioner with a 3.3 mm drill bit -1-.

Fig 13: Identifying Chain Tensioner Guide Rail Installed On Right Camshaft Timing Chain

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the chain tensioner -2- and camshaft chain sprocket -3- bolts -1-.

-- Remove the camshaft chain sprocket and chain tensioner.