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'timing slots' positioned at the rear of the camshafts.
Remove the air cleaner and both covers at the rear camshaft ends.
Remove the engine speed sensor and turn the crankshaft so that the 'slots' in the rear of camshafts are horizontal.
DT.4812 Tools can now be inserted into the 'timing slots' and secured in place with M6 bolts (hand tight only).
For valve timing adjustment, fi t the DT.4812 Camshaft Setting Tools and using a suitable Sprocket Holding Tool restrain the camshaft sprockets and slacken both
camshaft sprocket bolts.
Turn crankshaft to insert the DT.4813 Flywheel Locking Pin and re-tighten sprocket bolts.
1.8 & 1.8T Chain in Head Tensioner -Refer to Application Chart for model usage
This large V W range of 1.8 and 1.8 Turbo twin cam petrol engines, have a timing belt connecting the crankshaft to exhaust camshaft, and a timing chain
situated inside the cylinder head, driving the inlet camshaft from the exhaust camshaft.
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Timing belt replacement is straightforward. The plunger of the automatic tensioner must be compressed and retained by a pin to allow the belt to be removed.
This application is covered DT.4440T1 and DT.4593E1 tools from the DT.VAG Kit
On all these 1.8 and 1.8Turbo engines removal and refi tting of the valve gear, camshafts, timing chain etc. will require setting of the valve timing and DT.4809
Chain Tensioner Retainer will also be required
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DT.4809 Chain Tensioner Retainer
Valve timing
Prior to any dis-assembly, The crankshaft must be positioned at TDC No1. cylinder and the mark on the front camshaft sprocket must be aligned with the mark
on the cylinder head cover.
Mark with paint if necessary, the position of the chain links relative to the arrows on the camshaft rear bearing caps. The distance between arrows should be 16
rollers on the chain.
The head cover and timing belt can then be removed.
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Remove the camshaft front sprocket, using a counter-holding tool such as DT.CLE, to retain sprocket whilst releasing the bolt.
The notches on the camshaft must be aligned with the arrows on the bearing caps.
Fit Chain Tensioner Retainer DT.4809 to release tension off the chain.
WARNING: Do not over-tighten Retainer as damage to the tensioner can result.
IMPORTANT: When refi tting a chain, align the paint marks with the notch/arrows. A new chain must be fi tted so that the distance between the timing marks
(the arrows on bearing caps/notches on camshafts) should be 16 rollers on the chain.
Note however that the link being located onto the exhaust camshaft is slightly offset from the notch on the camshaft – see diagram 23.
Additional Tools Required
Diesel and Petrol Engines
Front Panel Support Guides -Refer to Application Chart for model usage
On a number of models, Audi A4, A6, A8, Volkswagen Passat, Touareg, for example, moving the front end out to "Service Position" is part of the timing belt
replacement procedure.
The front panel is released and moved forward to provide improved access to the engine. Remove the front panel bolts, fi t the Guides and slide panel forward.
Refi t the upper bolts to hold panel in position.
DT.4441 Front Panel Support Guides (in DT.VAG Kit) cover Audi A4, A6 and VW Passat models up to 10/2000.
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DT.4742 Front Panel Support Guides (Pair)
For later models and particularly V W Passat from 10/2000 onwards a revised design of Front End Support Guide is required – use DT.4742
Section 5:- UPDATED
Audi / V W
VAG Ref
DT. Ref
T10008
T10008
DT.4638
DT.4638
T10015
T10015
DT.4640T7
DT.4640T7
T10016
T10016
DT.4635
DT.4635
T10020
DT.4633
T10050
DT.4636
VAG Ref
DT. Ref
T10120
T10120
DT.4811
DT.4811
T10121
T10121
DT.4813
DT.4813
T10123
T10123
DT.4812
DT.4812
T20102
DT.4440V2
i
VAG Ref
AG Ref
DT. Ref
DT. Ref
VAG2065A
VAG2065A
DT.4115A-1
DT.4115A-1
VAG3242
VAG3242
DT.4401
DT.4401
VAG3359
VAG3359
DT.4440V2
DT.4440V2
VAG3366
DT.4809
VAG3369
DT.4441
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