Contents: Removal ⬇ Installation ⬇
Removal
1. Remove the lower protective cover of the engine compartment.
2. Drain the coolant into a previously prepared container.
3. Remove the right front wheel arch liner (for more details, see the corresponding section in the chapter Body).
4. Remove the poly V-belt of the accessory drive (more details, see the relevant section in this chapter).
5. Remove the upper timing chain cover (more details, see the relevant section in this chapter).
6. Loosen the mounting screws (1), remove the coolant pipe holder (2), as shown in the figure below.
7. Unscrew the threaded plug (arrow) on the cylinder block, as shown in the figure below.
8. Screw the "T10340" locking screw into the cylinder block until it stops, as shown in the figure below.
Attention.
- If you cannot screw in the "T10340" locking screw all the way, this means that the crankshaft is not in the correct position.
- In this case, follow the following procedure.
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9. Unscrew the locking screw.
10. Turn the crankshaft 90° (¼ turn) in the direction of engine shaft rotation.
11. Screw the fixing screw "T10340" into the cylinder block until it stops.
12. The "T10340" fixing screw should be tightened to a torque of 30 Nm.
13. Turn the crankshaft until it stops in the direction of rotation of the engine shaft.
14. Disconnect both coolant hoses (1) from the check valve as shown in the figure below.
15. Unscrew the fastening screw (2), remove the check valve from the cylinder head cover, as shown in the figure below.
16. Install the lock bolt "T10414" until it stops against the cylinder head cover.
17. Hand tighten the mounting screw shown in the figure below.
18. Remove the oil pan assembly.
19. Remove, if present, the dust cap (1), shown in the figure below.
20. Unscrew the mounting bolt and remove the guide roller (2), as shown in the figure below.
21. Unscrew the mounting bolts and remove the water pump drive pulley. When unscrewing the mounting bolts, hold the pulley from turning using a special device (V.A.G 1590).
22. Unscrew the mounting bolt and remove the crankshaft pulley.
23. Loosen all the fastening screws of the timing chain cover (1) and remove it carefully, as shown in the figure below.
24. Unscrew the tensioner (arrow) of the camshaft drive chain, as shown in the figure below.
25. Use a felt-tip pen to mark the direction of movement of the camshaft drive chain.
26. Holding the camshaft drive gear with the T10172 locking counter support, loosen the camshaft drive gear mounting bolt (1), as shown in the figure below.
27. Remove the camshaft drive gear together with the mounting bolt.
28. Remove the camshaft drive chain downwards.
Installation
1. Install the camshaft drive chain (1) from below onto the front crankshaft sprocket (2), guide it upwards between the guide rack and the tensioner rack, as shown in the figure below.
2. Secure the camshaft drive chain with a screwdriver (3) from falling off, as shown in the figure below.
3. Place the camshaft drive chain (1) onto the chain sprocket (2) as shown in the figure below.
4. On the guide rail section (3), the camshaft drive chain must fit snugly and be slightly taut.
5. Holding the camshaft drive gear with the T10172 locking counter support, tighten the camshaft drive gear mounting bolt (1) with a tightening torque of 50 Nm, as shown in the figure below.
Note: The mounting bolt should be turned 90° (¼ turn) only after checking the valve timing at the end of the working process.
6. Tighten the chain tensioner (arrow) to a torque of 60 Nm as shown in the figure below.
7. Remove the lock bolt "T10414" from the camshaft.
8. Unscrew the locking screw "T10340" from the cylinder block.
9. Turn the crankshaft two revolutions in the direction of rotation of the engine shaft.
10. Check the valve timing.
If the distribution over time is normal
11. Holding the camshaft drive gear using the T10172 locking counter support, turn the mounting bolt (1) 90° (¼ turn), as shown in the figure below.
12. Install the lower timing chain cover.
13. Install the oil pump drive chain cover (1) as shown in the figure below.
14. Install the oil pan.
15. Install the crankshaft pulley.
16. Install the poly V-belt for the accessory drive (more details, see the relevant section in this chapter).
17. Install the upper timing chain cover (more details, see the relevant section in this chapter).
18. Fill the cooling system with coolant.
19. Further installation is carried out in the reverse order of removal.