THESE ARE THE TOOLS U NEED TO HAVE AND PROCEDURE!!GOOD LUCK AND BEWARE THE TIMING..REPLACE BOTH CHAIN AND TENTIONER!!!!!!
Special tools and workshop equipment required
t Dial gauge -VAS 6079-
t Puller -T10094 A-
t Dial gauge adapter -T10170-
t Camshaft clamp -T10171-
t Counterhold tool -T10172-
t Locking pin -T40011-
t Spark plug spanner -3122 B-
t Counterhold tool -3415-
t Torque wrench (5...50 Nm) -V.A.G 1331-
Procedure
- Remove valve timing housing > Chapter.
- To turn crankshaft, reinstall bearing bush, crankshaft pulley -2- and crankshaft bolt -3- and securely tighten crankshaft bolt (use counterhold 3415).
- Remove spark plug from No. 1 cylinder. Use puller -T10094 A- and spark plug wrench 3122 B.
- Screw dial gauge adapter -T10170- into spark plug hole to stop.
- Screw dial gauge -VAS 6079- and extension -T10170/1- in to stop and lock in position with lock nut -arrow-.
- Turn crankshaft in direction of engine rotation, to TDC No. 1 cylinder. Note position of small needle on dial gauge.
- Then turn crankshaft back 45° opposite direction of engine rotation.
- Press tensioning guide rail -1- in direction of arrow and lock piston with locking pin -T40011-.
- Mark direction of rotation of timing chain -3- using felt-tip marker.
- Remove bolts -2- and remove camshaft sprocket -1- with timing chain -3-. Counterhold using counterhold tool -T10172-.
- Renew bolts -2-. Tighten bolt -2- to 50 Nm (use counterhold -T10172-).
- Turn inlet and exhaust camshafts until camshaft clamp -T10171- can be pushed into holes in camshaft to stop.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscription "TOP"-arrow 3- must be readable from above.
Note
Camshafts must not be pushed axially whilst turning.
- Install a M6 bolt -arrow- hand-tight (do not tighten) to secure camshaft clamp -T10171-.
- Remove camshaft sprocket bolts. It is absolutely necessary to use counterhold tool -T10172- for this.
Note
Camshaft clamp -T10171- must not be used as a counterhold tool.
- Remove one camshaft sprocket.
- Place timing chain over camshaft sprockets, observing chain direction of rotation, and install camshaft sprocket again.
- Tighten camshaft bolts until camshaft sprockets can still just be turned on camshafts.
- Tension timing chain by removing locking pin -T40011-.
- Turn crankshaft in engine direction of rotation to TDC No. 1 cylinder. Permissible deviation from TDC No. 1 cylinder: ±0.01 mm.
Note
If crankshaft is turned more than 0.01 mm past TDC, then turn crankshaft back 45° against engine direction of rotation. Then turn crankshaft in direction of engine rotation to TDC No. 1 cylinder.
- Hold camshaft sprockets -1- and -4- in this position with counterhold -T10172- then tighten bolts -2- to 50 Nm.
Note
Crankshaft must not move and timing chain -3- must remain tensioned on both sides when tightening camshaft bolts.
- Remove camshaft clamp -T10171-.
- Turn crankshaft two rotations in direction of engine rotation to TDC No. 1 cylinder. Permissible deviation from TDC No. 1 cylinder: ±0.01 mm.
- Insert camshaft clamp -T10171- to stop in camshaft openings.
If camshaft clamp -T10171- cannot be fitted
- Repeat adjustment.
If camshaft clamp -T10171- can be fitted
- Remove camshaft clamp -T10171-, hold camshaft sprockets with counterhold tool -T10172- and tighten bolts -2- a 1/4 turn (90°) further with a rigid wrench.
Note
Camshaft sprockets must not move on camshaft whilst tightening.
- Turn crankshaft two rotations again, in engine direction of rotation, to TDC No. 1 cylinder. Permissible deviation from TDC No. 1 cylinder: ±0.01 mm.
- Insert camshaft clamp -T10171- to stop in camshaft openings.
If camshaft clamp -T10171- cannot be fitted
- Repeat adjustment.
Further assembly is basically the reverse of the dismantling procedure. In the process, note the following:
t Installing valve timing housing > Chapter.
t Installing poly V-belt > Chapter.
t Renew oil seals for camshaft sealing cover and oil them before fitting.
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