Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft adjuster

Special tools and workshop equipment required

t	Allen key, long reach -T40080-

t	Camshaft clamp -T10252-

t	Locking pin -T10115-

t	2-hole pin wrench -T10020-

t	Torque wrench -V.A.G 1332-

Removing camshaft adjuster –  Remove high-pressure pump → Chapter. –  Remove cylinder head cover → Chapter.

–  Pull off coolant hoses -1 and 2-, unscrew bolt -3- and loosen coolant pipe from heat shield.

–  Unscrew cable retainer -arrow-.

–  Remove cover from camshaft adjuster -arrows-.

–  Align mark on camshaft toothed belt pulley with mark on toothed belt guard. The indentations -arrows- now point vertically to each other.

–  Fit camshaft clamp -T10252- as shown and secure -arrows-. –  Loosen securing bolt for camshaft adjuster using Allen key, long reach -T40080-.

–  Press chain tensioner together -arrow A- and secure it with locking pin -T10115--arrow B-. –  Remove securing bolt from camshaft adjuster and remove camshaft adjuster together with chain. Installing camshaft adjuster

l  The camshafts are located with the camshaft clamp -T10252-. –  Fit chain onto camshaft adjuster.

–  Hold camshaft adjuster in front of exhaust camshaft so that notch -A- and pin -B- align.

–  Lay chain over inlet camshaft chain sprocket starting at top -arrow- without changing its position.

–  Slowly turn inlet camshaft using 2-hole pin wrench -T10020- in direction of arrow -A- until the camshaft adjuster fits on the camshaft.   Note If pin does not fit into notch, remove chain and fit it again. –  Tighten camshaft adjuster securing bolt to 20 Nm + 1/8 turn (45°) further. Use Allen key, long reach -T40080- for this purpose.

–  Remove locking pin -T10115--arrow B-. Further assembly is basically the reverse of the dismantling sequence. –  Installing high-pressure pump → Chapter.