ToolGH29000/3366BulletinandNotes Application:1.8T,2.830V,2.7T30V,4.2L Pleasereadthefollowinginstructionstoavoiddamaging ToolGH29000/3366. **DISCLAIMER** Thecamchaintensionerandchainprocedureispartofaverycomplexrepairandistobeperformedby*experienced*automotivetechnicianswhoaretrainedin performingpropercamchaintensionerandchainprocedures. Therefore,BLAUfergnugen!Inc.recommendsthataFactory Audi/Vw ASECertified Technician,whois trainedinthecorrectcamchaintensionerandchainproceduresforyourspecificvehiclemodelperformthisprocedureonyourvehicle. Thisistoensureyoursafety andpreventimproperinstallation/repairbyuntrainedandunqualifiedinstallers,includingtechnicians,whichmightleadtopossibleenginedamage. -Alwaysreadthefactoryservicemanualsafetyinstructionsandguidelines. -Alwayswearsafetyglassesandothersafetyitems/equipmentwhenperformingthefollowingwork. 1. Thread Tool3366intothelowerportionofthecamchaintensioneraspictured.Donotcompressatthistime. 2.Duetothecamchaintensionerbeingfilledwithoilpressure,itmaybedifficulttocompressthecamchaintensioner. Toavoid breakingtheplasticportionof Tool3366,loosen4camchaintensionerbolts2-3fullturns.Begincompressingcamchaintensioner with Tool3366.Oncetoolcompressionbecomesdifficult,allow15-20secondstopassforeverycompressionturnof Tool3366. This willallowoilpressuretoberelievedfromthecamchaintensioner. Thiscanminimizechancesofdamage,tothecamchain tensioneror Tool3366. 3. Tool3366isdesignedtorelievetensionfromthecamchain.Donotbottomoutthreadsof Tool3366whencompressingcam chaintensioner. Page1Copyright© BLAUfergnügen!Inc.2013FormIns168Revised 4/25/13 GuidelinesForInstallationOfValveCoverGasketKitGF21002 **DISCLAIMER** Thecamchaintensionerandchainprocedureispartofaverycomplexrepairandistobeperformedby*experienced*automotivetechnicianswhoaretrainedin performingpropercamchaintensionerandchainprocedures. Therefore,BLAUfergnugen!Inc.recommendsthataFactory Audi/Vw ASECertified Technician,whois trainedinthecorrectcamchaintensionerandchainproceduresforyourspecificvehiclemodelperformthisprocedureonyourvehicle. Thisistoensureyoursafety andpreventimproperinstallation/repairbyuntrainedandunqualifiedinstallers,includingtechnicians,whichmightleadtopossibleenginedamage. -Alwaysreadthefactoryservicemanualsafetyinstructionsandguidelines. -Alwayswearsafetyglassesandothersafetyitems/equipmentwhenperformingthefollowingwork. ThefollowinginformationissimplyaguidelineandisnotintendedtoreplacetheofficialFactoryManual. Alwaysrefertothefactorymanualforproperinstallationandsafetyguidelines. 1) Beforeproceeding,followallguidelinesfortheproperremovalofyourtimingbelt. 2) Removealldecorativeenginecovers. 3) Removethefrontairboxintaketubing. 4) Removetheintakethrottlebodypipeonthepassengerssideofthemotor.(2.7T MODELS-Removeintake Y pipe.(3)10mmfastenersholding thecentersectioninplaceand(1)10mmfasteneroneachvalvecover.) 5) Removefastenersandcoolantlevelwireplugfromcoolantexpansiontankandplacecoolantexpansiontankofftothesideofengine compartment,stillkeepingthehosesconnected. 6) (2.8MODELSONLY) Removeoildipstickboltsothatthedipstickcanbepushedofftotheside.(one13mmfastener) 7) Unplugthemassairflowsensorplug,alongwithremainingcomponentplugsontopofairbox. 8) Remove10mmfastenerlocatedoninnerfender,holdingairboxinplace.Pullupwardandremovetheairbox. 9) Referencethelocationofeachsparkplugwire/coil,thenpullthemupandout,placeofftotheside.Ifyoufeelmorecomfortabledoone valvecovergasketatatimeastonotmixupsparkplugwiresorcoils. 10) Removethebreatherhosethatrunsfromonevalvecovertotheothervalvecover,aswellasthebreatherhosesonthebacksideofthevalve covers. 11) Removethecamshaftgearpulley. 12) Removetimingbeltbackingcover. 13) UnplugandremovetheCamshaftPositionSensor. 14) (FOR2.7TMODELSONLY) Onsome2.7T modelstheCombinationValvewill beinthewayofremovingthevalvecoverandtherearcamcap.Becauseofthis, theywillneedtoberemoved.Unfortunately,thiswillbeadifficulttaskbecauseof tightspace.Morethenlikely,youwillneedtoremovethismorebytouchthen sight.RemovethevacuumhoseandplasticpipefromeachCombinationValve. TheCombinationValvealongwiththegasketareheldinplaceby3allantype (Image1) fasteners. (Image1) (Onsome2.7TmodelsyouwillnotneedtoremovetheCombinationValve.Checkperyourvehicle.) Page2Copyright© BLAUfergnügen!Inc.2013FormIns168Revised 4/25/13 GuidelinesForInstallationOfValveCoverGasketKitGF21002continued.......... 14) Removeallofthe10mmnutsonthevalvecover.Usingarubbermallet,lightlytaponthevalvecovertobrakeloose.Removethevalve cover.Onthepassengerssidecylinderheadyouwillneedtoremovethe10mmboltholdingthep/shoseinplace,prytheseupwardalongwith thefuellines. (Image2) 15) Whenthevalvecoverisoff,slideinthespecialtool TR016(3366)intobottomsideofcamchaintensionerandverylightlytorque. Thiswill allowthetensiononthecamchaintoberelieved. (Image3) (DONOTOVERTIGHTENTOOL.MAY DAMAGECAMCHAINTENSIONERORTOOL.) 16) Removethefourtorxonthetensionerandgentlypulluponittoseparateitfromthecylinderhead. (Image4) (Image2) (Image3) (Image4) 17) Checktoseeiftimingmarksonthecamshaftslineupsimultaneouslywiththearrowsoncamcaps. Cleancamandchainwithsolvent,mark timingmarksandcamchainwithpaintorsimilarforbetterobservation. (Image5and6) (Passengersidecylinderhead: Distancebetweencamshaftmarksis16camchainrollers.) (Driversidecylinderhead: Distancebetweencamshaftmarksis15-151/2camchainrollers.Exhaustcammarkwillbeataslightangle.) 18) Removecamcaps1-3-5-7andplaceonacleanbenchinpropernotedorder . (Image7) (IFCAMCAPS ARENOTINSTALLEDCORRECTLY ASINPROPERNOTEDORDER,THISWILL CAUSEDAMAGETOTHEENGINE) 19) Loosencamcaps2-and4-evenly,thenremove.Repeatstepon2ndcamshaft. (Image7) (Image5) (Image6) (Image7) Page3Copyright© BLAUfergnügen!Inc.2013FormIns168Revised 4/25/13 GuidelinesForInstallationOfValveCoverGasketKitGF21002continued.......... 20) Removebothcamshaftstogetherwithcamtensioner. (A secondpersonssetofhandsisbesttoensurenodamagetothecamtensionerduringremovalandinstallation.) 21) Cleanallgasketsurfacesandinstallnewcamchaintensionerseals.Betweencamtensionergasketandhalfmoonseal. Applyalightcoatof hightempsiliconegasketcompound.Wheninstallingcamtensionergasketmakingsureitpopsdownoverthealignmentpins.(Image8and9) 22) Beforeinstallingcamshaftscheckpositionofmarksonthechainandcams. (Passengersidecylinderhead: Distancebetweencamshaftmarksis16camchainrollers.) (Driversidecylinderhead: Distancebetweencamshaftmarksis15-151/2camchainrollers.Exhaustcammarkwillbeataslightangle.) 23) Installbothcamshaftsalongwithcamtensionerasoneunittogetherintocylinderhead. 24) Beforesecuringcamshaftscheckpositionsofmarksonthechainandcamsasecondtime. 25) Atthistimeitsbesttolubricateyourcamseals,camreferencesensorseals,andslidetheseintoplace.Usingassemblyoilorgreaseonthe innersealsurfaceandnotontheODofthesealisbest.Slideinuntilsealbottomsoncylinderhead. 25) Usingassemblyoilorgreaseinstallcamcaps2-and4-evenlyandtighteninadiagonalsequence. TorqueSpec7ftlbs. 26) Beforeinstallingcamcap7onthepassengerssidecylinderheadandorcamcap1onthedriverssideyouwillwanttoinstallyourcamshaft sealplugsintoplace.Insomecasesitisbesttolightlycoattheplugwithsomehightempsilicononthesealingsurface. (Image10) . (Image8) (Image9) (Image10) RelatedTorqueSpecs Camshaftsprocketbolt-41ftlbs. 13mmCamshaftreferencesensorboltwithconicalwasher-18ftlbs Reartimingbeltcover-7ftlbs. Camshaftreferencesensor-7ftlbs. Valvecover-7ftlbs. CombinationValve-7ftlbs. Page4Copyright© BLAUfergnügen!Inc.2013FormIns168Revised 4/25/13 GuidelinesForInstallationOfValveCoverGasketKitGF21002continued.......... 27) Lightlycoatthebottomsurfacesofcamcaps1and7withhightempsilicongasket compoundattheoutersideofthecylinderheadandinstall. TorqueSpec7ftlbs. (Image11and12) 28) Usingassemblyoilorgreaseinstalltheremainingcamcaps. TorqueSpec7ftlbs. 29) Torquecamtensionertospec. TorqueSpec7ftlbs. 30) Removecamtensionerspecialtool TR016(3366)anddoublecheckthecamshafttiming marks. (Image11) 31) Carefullycleanthematingsurfacesofthevalvecoverandcylinderhead.PleaseNote:It’s importantthatthegasketsurfacesareperfectlyclean.Witharagorsmallpick,cleanoutall smallgrooves. 32) BULLETINPLEASENOTE: Applyasufficientamountofhightempsilicongasket compoundtothebottomandtopcornerareasofthevalvecovergasketmatingsurfacesas notedinimage13. Applyasufficientamountofhightempsilicongasketcompoundtothe (Image12) bottomofthevalvecovergasketinthecamchaintensionerandcamcapcenterarea.Failure tofollowtheabovenotedcancauseoilleaks! (Image13) 33) Oncethisprocesshasbeenaccomplished ononecylinderheadsuccessfully,repeatthe sameprocessonthesecondcylinderhead. 34) Forremainingassembly,reversethe abovesteps. (Image13) Page5Copyright© BLAUfergnügen!Inc.2013FormIns168Revised4/25/13.