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Elsa online. ElsaWin. ElsaWeb. VW trucksPower unit5-cylinder diesel engineEngine cylinder head, valve gearValve gearRemoving and installing camshaft drive gear

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Removing and installing camshaft drive gear
Special tools and workshop equipment required
t  Special wrench, long reach -T10198-
t  Clamp -T10199-
t  Thrust piece -T10199/1-
t  Special wrench -T10211-
t  Socket -T10234-
t  Torque wrench -V.A.G 1331- (5...50 Nm)
t  Torque wrench -V.A.G 1332- (40...200 Nm)
t  Torque wrench, 50-100 Ncm -VAS 6253-
Removing
–  Set engine to TDC no. 1 cylinder → Chapter.
–  Remove charge air pipes between charge air cooler/turbocharger and charge air cooler/intake connecting pipe.
–  Remove intake manifold support.
–  Remove exhaust gas recirculation connecting pipe.
–  Remove engine cover panel and cylinder head cover → Item.
–  Remove tandem pump → Rep. gr.20.
–  Detach central connector of unit injectors and release connector on cylinder head using wrench -T10211-
    
–  Remove outer bearing cap -A-. Mount clamping device -T10199- on camshaft sprocket and tighten its bolts to 40 Nm.
–  Loosen camshaft sprocket securing bolt -B- using XZN 16 bit -T10198- and unscrew together with tandem pump shaft.
–  Remove camshaft sprocket from camshaft.
–  Remove Hall sender -G40--C- for camshaft position.
–  Unscrew cap from eccentric pin.
–  Loosen securing bolt -D- and withdraw eccentric pin.
–  Carefully remove camshaft drive gear together with balancer plate.
Installing
Installation is carried out in the reverse order; note the following:
  Caution
The engine can be damaged.
When installing a diamond-coated washer which has already been used, the drive pulley cannot be properly secured to the camshaft.
Use new diamond-coated washer!
   N15-10071
–  Lubricate entire surface of guide sleeve -4-.
–  Mount camshaft drive gear -3- on guide sleeve.
–  Fit washer -2- as shown.
  Note
The lugs of the disc must engage in the grooves of the guide sleeve
–  Mount camshaft drive gear with washer and guide sleeve on balancer plate -1-.
  Note
   N15-10050
The marks -A- on the guide sleeve and the balancer plate must align.
   N15-10030
–  Carefully insert balancer plate with camshaft drive gear from top into gear chamber.
–  Lubricate entire surface of eccentric pin. -5-.
   N15-10050
–  Install eccentric pin. The marking -B- on the eccentric pin must point vertically upwards.
  Note
Marking -C- must align with sealing surface of cylinder head.
–  Install outer bearing cap and tighten hand tight.
   N15-10030
–  Install new securing bolt -6- for eccentric pin and tighten by hand until approx. one turn before limit stop.
–  Apply insert tool -T10234- with torque wrench 50-100 Ncm -VAS 6253- in eccentric pin holes.
   N15-10050
–  Carefully turn eccentric pin anticlockwise with 50 Ncm.
–  Hold eccentric pin in this position and tighten new eccentric pin securing bolt.
–  Remove outer bearing cap again.
–  Place central connector of unit injectors carefully into cylinder head.
–  Install outer bearing cap with sealant and tighten using new bolts.
  Note
Seal parting surfaces of outer bearing caps with silicone sealant -D 176 501 A1- → Fig.
–  Lock central connector using wrench -T10211-.
–  Screw caps of eccentric pin and Hall sender -G40- tight.
  Note
t  Check that the washer is seated correctly on the camshaft before installing the camshaft sprocket.
t  The teeth of the camshaft sprocket must be lubricated all over.
   N15-10049
–  Locate camshaft sprocket on camshaft such that marking on sender wheel -arrow- aligns with upper edge of cylinder head sealing surface.
–  Secure camshaft gear wheel and tandem pump shaft using new bolt and tightening hand tight. (Camshaft gear wheel can still turn).
   N15-0670
–  Locate clamping tool -T10199/1- as shown and tighten clamping bolts to 70 Nm.
–  Fit torque wrench -V.A.G 1332- into square drive of clamping tool and exert force of 80 Nm counter to direction of engine rotation to remove play from gear train.
–  Maintain specified force and tighten camshaft sprocket securing bolt -A- to torque of 50 Nm using XZN 16 bit -T10198-.
   N15-10171
–  Remove clamping tool -T10199/1-.
–  Place clamping device -T10199 - on camshaft sprocket.
  Note
Ensure the clamp -T10199- lies flush with the cylinder head.
–  Tighten bolts of clamping device -T10199- to 40 Nm.
–  Then secure camshaft gear wheel using socket XZN 16 -T10198-.
–  Remove clamping device -T10199-.
–  Remove clamps from camshaft and crankshaft.
–  Install tandem pump → Rep. gr.20.
–  Install cylinder head cover and engine cover panel → Item.
–  Turn crankshaft two revolutions further in direction of engine rotation until crankshaft is again set to TDC no. 1 cylinder.
–  Check that camshaft and crankshaft clamps can be inserted.
–  Fit new sealing cover for camshaft.
–  Fit new sealing cover for crankshaft.
–  Install charge air pipes between charge air cooler/turbocharger and charge air cooler/intake connecting pipe.
–  Install intake manifold support.
–  Install exhaust gas recirculation connecting pipe.
Specified torques
t  → Chapter „Assembly overview - valve gear“
t  → Chapter „Assembly overview - cylinder head“
   N15-10071


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