Tool GH29000 / 3366 Bulletin and Notes

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1 Tool GH29000 / 3366 Bulletin and Notes Application: 1.8T, V, 2.7T 30V, 4.2L Please read the following instructions to avoid damaging Tool GH29000/3366. **DISCLAIMER** The cam chain tensioner and chain procedure is part of a very complex repair and is to be performed by *experienced* automotive technicians who are trained in performing proper cam chain tensioner and chain procedures. Therefore, BLAUfergnugen! Inc. recommends that a Factory Audi/Vw ASE Certified Technician, who is trained in the correct cam chain tensioner and chain procedures for your specific vehicle model perform this procedure on your vehicle. This is to ensure your safety and prevent improper installation/repair by untrained and unqualified installers, including technicians, which might lead to possible engine damage. -Always read the factory service manual safety instructions and guidelines. -Always wear safety glasses and other safety items/equipment when performing the following work. 1. Thread Tool 3366 into the lower portion of the cam chain tensioner as pictured. Do not compress at this time. 2. Due to the cam chain tensioner being filled with oil pressure, it may be difficult to compress the cam chain tensioner. To avoid breaking the plastic portion of Tool 3366, loosen 4 cam chain tensioner bolts 2-3 full turns. Begin compressing cam chain tensioner with Tool Once tool compression becomes difficult, allow seconds to pass for every compression turn of Tool This will allow oil pressure to be relieved from the cam chain tensioner. This can minimize chances of damage, to the cam chain tensioner or Tool Tool 3366 is designed to relieve tension from the cam chain. Do not bottom out threads of Tool 3366 when compressing cam chain tensioner. Page 1 Copyright BLAUfergnügen! Inc Form Ins168 Revised 4/25/13

Guidelines For Installation Of Valve Cover Gasket Kit GF21002 **DISCLAIMER** The cam chain tensioner and chain procedure is part of a very complex repair and is to be performed by *experienced*

2 Guidelines For Installation Of Valve Cover Gasket Kit GF21002 **DISCLAIMER** The cam chain tensioner and chain procedure is part of a very complex repair and is to be performed by *experienced* automotive technicians who are trained in performing proper cam chain tensioner and chain procedures. Therefore, BLAUfergnugen! Inc. recommends that a Factory Audi/Vw ASE Certified Technician, who is trained in the correct cam chain tensioner and chain procedures for your specific vehicle model perform this procedure on your vehicle. This is to ensure your safety and prevent improper installation/repair by untrained and unqualified installers, including technicians, which might lead to possible engine damage. -Always read the factory service manual safety instructions and guidelines. -Always wear safety glasses and other safety items/equipment when performing the following work. The following information is simply a guideline and is not intended to replace the official Factory Manual. Always refer to the factory manual for proper installation and safety guidelines. 1) Before proceeding, follow all guidelines for the proper removal of your timing belt. 2) Remove all decorative engine covers. 3) Remove the front air box intake tubing. 4) Remove the intake throttle body pipe on the passengers side of the motor. (2.7T MODELS - Remove intake Y pipe. (3) 10mm fasteners holding the center section in place and (1) 10mm fastener on each valve cover.) 5) Remove fasteners and coolant level wire plug from coolant expansion tank and place coolant expansion tank off to the side of engine compartment, still keeping the hoses connected. 6) (2.8 MODELS ONLY) Remove oil dip stick bolt so that the dip stick can be pushed off to the side.(one 13mm fastener) 7) Unplug the mass air flow sensor plug, along with remaining component plugs on top of air box. 8) Remove 10mm fastener located on inner fender, holding air box in place. Pull upward and remove the air box. 9) Reference the location of each spark plug wire/coil, then pull them up and out, place off to the side. If you feel more comfortable do one valve cover gasket at a time as to not mix up spark plug wires or coils. 10) Remove the breather hose that runs from one valve cover to the other valve cover, as well as the breather hoses on the backside of the valve covers. 11) Remove the camshaft gear pulley. 12) Remove timing belt backing cover. 13) Unplug and remove the Camshaft Position Sensor. 14) (FOR 2.7T MODELS ONLY) On some 2.7T models the Combination Valve will be in the way of removing the valve cover and the rear cam cap. Because of this, they will need to be removed. Unfortunately, this will be a difficult task because of tight space. More then likely, you will need to remove this more by touch then sight. Remove the vacuum hose and plastic pipe from each Combination Valve. The Combination Valve along with the gasket are held in place by 3 allan type fasteners. (Image 1) (Image 1) (On some 2.7T models you will not need to remove the Combination Valve. Check per your vehicle.) Page 2 Copyright BLAUfergnügen! Inc Form Ins168 Revised 4/25/13

14) Remove all of the 10 mm nuts on the valve cover. Using a rubber mallet, lightly tap on the valve cover to brake loose.

On the passengers side cylinder head you will need to remove the 10mm bolt holding the p/s hose in place, pry these upward along

(Image 2) 15) When the valve cover is off, slide in the special tool TR016 (3366) into bottom side of cam chain tensioner and very

(Image 4) (Image 2) (Image 3) (Image 4) 17) Check to see if timing marks on the camshafts line up simultaneously with the arrows

(Image 5 and 6) ( Passenger side cylinder head: Distance between camshaft marks is 16 cam chain rollers.

3 14) Remove all of the 10 mm nuts on the valve cover. Using a rubber mallet, lightly tap on the valve cover to brake loose. Remove the valve cover. On the passengers side cylinder head you will need to remove the 10mm bolt holding the p/s hose in place, pry these upward along with the fuel lines. (Image 2) 15) When the valve cover is off, slide in the special tool TR016 (3366) into bottom side of cam chain tensioner and very lightly torque. This will allow the tension on the cam chain to be relieved. (Image 3) (DO NOT OVER TIGHTEN TOOL. MAY DAMAGE CAM CHAIN TENSIONER OR TOOL.) 16) Remove the four torx on the tensioner and gently pull up on it to separate it from the cylinder head. (Image 4) (Image 2) (Image 3) (Image 4) 17) Check to see if timing marks on the camshafts line up simultaneously with the arrows on cam caps. Clean cam and chain with solvent, mark timing marks and cam chain with paint or similar for better observation. (Image 5 and 6) ( Passenger side cylinder head: Distance between camshaft marks is 16 cam chain rollers.) ( Driver side cylinder head: Distance between camshaft marks is /2 cam chain rollers. Exhaust cam mark will be at a slight angle.) 18) Remove cam caps and place on a clean bench in proper noted order. (Image 7) (IF CAM CAPS ARE NOT INSTALLED CORRECTLY AS IN PROPER NOTED ORDER, THIS WILL CAUSE DAMAGE TO THE ENGINE) 19) Loosen cam caps 2- and 4- evenly, then remove. Repeat step on 2nd camshaft. (Image 7) (Image 5) (Image 6) (Image 7) Page 3 Copyright BLAUfergnügen! Inc Form Ins168 Revised 4/25/13

20) Remove both camshafts together with cam tensioner. (A second persons set of hands is best to ensure no damage to the cam tensioner during removal and installation.

When installing cam tensioner gasket making sure it pops down over the alignment pins. (Image 8 and 9) 22) Before installing camshafts check position of marks on the chain and cams.

Exhaust cam mark will be at a slight angle.) 23) Install both camshafts along with cam tensioner as one unit together into cylinder head.

4 20) Remove both camshafts together with cam tensioner. (A second persons set of hands is best to ensure no damage to the cam tensioner during removal and installation.) 21) Clean all gasket surfaces and install new cam chain tensioner seals. Between cam tensioner gasket and half moon seal. Apply a light coat of high temp silicone gasket compound. When installing cam tensioner gasket making sure it pops down over the alignment pins. (Image 8 and 9) 22) Before installing camshafts check position of marks on the chain and cams. ( Passenger side cylinder head: Distance between camshaft marks is 16 cam chain rollers.) ( Driver side cylinder head: Distance between camshaft marks is /2 cam chain rollers. Exhaust cam mark will be at a slight angle.) 23) Install both camshafts along with cam tensioner as one unit together into cylinder head. 24) Before securing camshafts check positions of marks on the chain and cams a second time. 25) At this time its best to lubricate your cam seals, cam reference sensor seals, and slide these into place. Using assembly oil or grease on the inner seal surface and not on the OD of the seal is best. Slide in until seal bottoms on cylinder head. 25) Using assembly oil or grease install cam caps 2- and 4- evenly and tighten in a diagonal sequence. Torque Spec 7 ft lbs. 26) Before installing cam cap 7 on the passengers side cylinder head and or cam cap 1 on the drivers side you will want to install your camshaft seal plugs into place. In some cases it is best to lightly coat the plug with some high temp silicon on the sealing surface. (Image 10). (Image 8) (Image 9) (Image 10) Related Torque Specs Camshaft sprocket bolt-41ft lbs. 13mm Camshaft reference sensor bolt with conical washer-18ft lbs Rear timing belt cover-7ft lbs. Camshaft reference sensor-7ft lbs. Valve cover-7ft lbs. Combination Valve-7ft lbs. Page 4 Copyright BLAUfergnügen! Inc Form Ins168 Revised 4/25/13

27) Lightly coat the bottom surfaces of cam caps 1 and 7 with high temp silicon gasket compound at the outer side of the cylinder head and install. Torque Spec 7 ft lbs.

(Image 11) 31) Carefully clean the mating surfaces of the valve cover and cylinder head. Please Note: It s important that the gasket surfaces are perfectly clean.

32) BULLETIN PLEASE NOTE: Apply a sufficient amount of high temp silicon gasket compound to the bottom and top corner areas of the valve cover gasket mating surfaces as noted in image 13.

5 27) Lightly coat the bottom surfaces of cam caps 1 and 7 with high temp silicon gasket compound at the outer side of the cylinder head and install. Torque Spec 7 ft lbs. (Image 11 and 12) 28) Using assembly oil or grease install the remaining cam caps. Torque Spec 7 ft lbs. 29) Torque cam tensioner to spec. Torque Spec 7 ft lbs. 30) Remove cam tensioner special tool TR016 (3366) and double check the camshaft timing marks. (Image 11) 31) Carefully clean the mating surfaces of the valve cover and cylinder head. Please Note: It s important that the gasket surfaces are perfectly clean. With a rag or small pick, clean out all small grooves. 32) BULLETIN PLEASE NOTE: Apply a sufficient amount of high temp silicon gasket compound to the bottom and top corner areas of the valve cover gasket mating surfaces as noted in image 13. Apply a sufficient amount of high temp silicon gasket compound to the bottom of the valve cover gasket in the cam chain tensioner and cam cap center area. Failure (Image 12) to follow the above noted can cause oil leaks! (Image 13) 33) Once this process has been accomplished on one cylinder head successfully, repeat the same process on the second cylinder head. 34) For remaining assembly, reverse the above steps. (Image 13) Page 5 Copyright BLAUfergnügen! Inc Form Ins168 Revised 4/25/13

PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT

PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT Bulletin: Prevent Premature Water Pump Failure! BLAUfergnugen! Inc. recommends that an Audi Vw Factory Trained ASE