MK5 Golf GTI

All Things Mk5 => How to Guides / Troubleshooting => Topic started by: rich83 on April 11, 2016, 03:31:54 PM

Title: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 11, 2016, 03:31:54 PM
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/Tools%20and%20Parts.jpg)

1. Cam Cover Gasket  06F 103 483 D
2. Tensioner 06F 109 217 A
3. Adjuster Bolt 06D 109 281 D
4. Cam Chain 06D 109 229 B
5. Tensioner Bolts  N 101 963 03 (optional) x3
6. Rear PCV Clamp N 904 096 01 OR. 30mm jubilee clip
7. Cam Chain Cover Bolts N 101 243 08 (Optional) x7
8. Cam Chain Cover Gasket 06D 103 121 B
9. 600mm 1/2" Breaker Bar
10. 3/8" Ratchet
11. 1/2" Ratchet
12. Low Range Torque Wrench
13. 1/2" Torque Wrench
14. 16mm Spark Plug Socket
15. 1/4-3/8-1/2" Adapters
16. VW Tool T10020
17. VW Tool T40080
18. VW Tool T10252
19. 3/8" Long Torx bits
20. 1/4" Socket Set

Extra tools not shown.... Pliers, Mole grips, flat blade screwdriver. M5 multispline

Other bits in pic are for an oil change, which I will do after the chain is done.



MYSELF OR MK5GOLFGTI.CO.UK CANNOT BE HELD RESPONSINBLE FOR DAMAGE TO YOU CAR. FOLLOW THIS GUIDE AT YOUR OWN RISK

Should look something like this to begin with. I will skip the removal of the intake as everyone has a different setup. If you have the OEM box, google how to remove it
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/1.jpg)



REMOVING THE BATTERY

10mm socket or spanner. Do the neg. first then the pos.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/2.jpg)

Remove the 13mm retaining bolt/plate
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/3.jpg)

Remove the plastic cover on the front of the battery and then the battery can be pulled out

Remove the 3x 10mm bolts holding the battery tray in.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/4.jpg)

Should look like this now
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/5.jpg)

Always put something over the turbo inlet to stop crap falling in.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/8.jpg)



REMOVING THE COILPACK LOOM AND COILPACKS

Use a flat blade screwdriver to unclip the connectors. BE VERY CARFUL WITH THE CLIPS, THEY BREAK EASILY
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/9.jpg)

Remove the coils. You can number them if you are OCD. No real need though
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/10.jpg)

REMOVING THE FRONT PCV

Undo the 4x T25 torx screws. And remove the front corrugated plastic pipe that links the PCV to the intake manifold
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/11.jpg)

Remove the rightmost pipe on the PCV. Squeeze the 2 tabs on either side of the connector (marked in the pic)
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/12.jpg)

Should look like this.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/IMG_7410.jpg)

Remove the thin pipe in the centre of the cam cover. Squeeze either side as before.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/13.jpg)



REMOVING THE CAM COVER

All T30 Torx. Start with 2x on the left side over the cambelt
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/14.jpg)

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/15.jpg)

Remove the 14x T30 bolts on top of the cam cover.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/16.jpg)

Now... this bits a bit tricky, because you have to remove the 2 rear PCV hoses. I started by using a thin flat blade screwdriver to get under them and break the seal. I also used a pair of pliers very carefully around the thinner pipe to twist it. You should be able to get the thinner pipe off. I am not going to lie, this bit was a pain in the ass. Just perceiver and you'll get it off.

Remove the large pipe clamp by inserting a flat blade screw driver into the hole and twisting.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/17.jpg)

Leave the fat pipe on for now.

Lets break the cam cover seal. Best way to do this is kneel infront of the car and place both hands (as marked below) on the edge of the cover and slowly but firmly push up and away.  Just be carful not to snap the neck off the filler pipe.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/18.jpg)

Once you've broken the seal you should be able to lift up the cover, this should help you release that rear fat PCV pipe by twisting and jiggling it.... again... this bit is a pain.


Once you have done that, its a good idea to spend a bit of time cleaning up the mating surface as it will be quite oily and will be dirty especially on the front edge.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/19.jpg)



REMOVING THE HPFP

This is well documented online, so will keep this short

Link to thread to show you how.
http://www.mk5golfgti.co.uk/forum/index.php/topic,8339.0.html

You'll need a T30 torx screwdriver and a 13mm spanner.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/20.jpg)



REMOVING THE CAM CHAIN COVER

Begin by removing the bracket for the coolant line. M5 multispline is required here.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/21.jpg)

Remove the connector for the N205 cam adjuster valve. Also unclip the clips for the fat loom that runs beneath the cover
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/22.jpg)

Pull off the vacuum connector on the front of the cover. This is quite stubborn but it will pull straight off.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/23.jpg)

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/24.jpg)

Remove the bracket from below the cover. T30 Torx
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/25.jpg)

Undo the 7x T30 torx bolts holding on the cam chain cover. All bolts are black. Do not undo the silver bolt at the bottom by accident.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/26.png)

Note. You will need the 100mm torx bits ITEM NUMBER 19 at the start of the post, you will not manage the lower bolt without these

Before we remove the cover its important to move the coolant line clear of the N205 valve. Gently bend the metal pipe upwards.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/27.jpg)

Place lots of towels down below the cover, this bit can be quite messy and its good to prevent oil spilling all over the gearbox housing.

The cam cover can now be carefully removed, pull it off as straight as possible.

Stand back and admire how well you have done.

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/28.jpg)



LOCKING THE CAMS

Its a good idea to remove the plugs. Youll need a long 16mm spark plug socket.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/29.jpg)

Its a good idea to cover the cam area just to stop any dirt getting into that area.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/30.jpg)

Insert the tool T10020 into the intake cam lobe and rotate it until the notches on both cams are facing each other, the locking tool should slot in.

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/32.jpg)

Now, the locking tool is a bit sh*t and there will be some play as it doesnt fit tightly between the cams. What I did was slide the locker as far back towards the exhaust cam as possible and tighten the two bolts up to 7 ftlbs

Just for extra peace of mind its worth marking the cams with a permanent marker pen. This gives you peace of mind that you have put the chain back on correctly. Mark directly on the cam, and on the cam cap right next to each other as show below. There are helpful little arrows to assist you with this.

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/33.jpg)

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/34.jpg)



REMOVING THE ADJUSTER AND CHAIN

OK... this is the bit you have been dreading. I woke up in cold sweats thinking about this part.

Remove the tensioner pin off the new tensioner and place it in the same hole on the old one, just to stop it exploding (see pic below)
Using the tool T40080 and a long (~600mm) 1/2" breaker bar its time to crack the adjuster bolt. You WILL need a long bar, a normal 1/2" ratchet will not be sufficient.

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/35.jpg)

This will make one hell of a noise when it moves and it will require to you use a lot of force. With your right palm keep the tool in the adjuster bolt (I grabbed around the adjuster with my fingers) and with your left hand smoothly pull.... HARD!!! No sudden jerks.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/36.jpg)

(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/37.jpg)

You will notice that when you pull to undo the bolt the cams will very slightly move. This is why we marked them earlier. You can see that the cams have slightly moved, but no panic as they have moved the same amount.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/timing%20marks.jpg)

At this point I suggest you have a break.... Once you get here you have broken the back of the job, all the hard/worrying stuff has been done.

Continuing undoing the adjuster bolt by hand with tool T10020 and remove it.

Pull off the adjuster and the chain should come off with it, just be a bit carful here so you dont damage any teeth or the adjuster (its expensive)
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/38.jpg)

Now you can undo the 3x T30 torx bolts that hold on the tensioner.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/39.jpg)

Old vs New
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/40.jpg)



REPLACING THE TENSIONER AND CHAIN

Bolt on the new tenstioner, and torque to 7 ftlbs (I used new bolts)
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/41.jpg)

Its a good idea to give the adjuster locating hole/surface a clean. Also clean up the mating surface of the cam chain seal/gasket. Failure to do this could result in leaks.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/42.jpg)

You can see that there is a notch in the adjuster mating surface, the adjuster can only go on one way. Before we put the chain on its a good idea to offer up the adjuster and mark on the top of the adjuster with a pen so you can use this as a reference when fitting it back with the chain.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/43.jpg)

Loop the chain onto the adjuster and carefully place the other end of the chain over the intake gear. This is where the mark will come in handy as you will be able to see very quickly if you have the chain on the right link or not. It took me a few goes to get this right. You might need to very slightly rotate the intake cam clockwise to enable the adjuster to slot in correctly. Just be patient.

YOU CANNOT GET THIS BIT WRONG.... IF YOU DO, YOU WILL CAUSE CATASTROPHIC ENGINE DAMAGE. IF YOU ARE NOT SURE THEN DO NOT CONTINUE UNTIL YOU CAN GET A SECOND OPINION ON THIS

Once the new chain is on it should look something like this.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/44.jpg)

You can now remove the locking pin from the tensioner.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/45.jpg)

Insert the new adjuster bolt and tighten. This is a 2 stage tightening process.

STAGE 1
Tighten to 15 ftlbs using a torque wrench.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/46.jpg)

STAGE 2
Next is to put 1/8th turn on the bolt. If you have an angle gauge then use it to tighten to 1/8th turn (45º) and skip this bit, if you don't have one then keep reading.

Put the T40080 tool on your breaker bar. and have it in a position so that it can be rotated. I.E. not so high that you cannot tighten the bolt.

With the tool in the adjuster bolt, mark the tool and the adjuster with a marker pen. Marked 'A' below.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/47.jpg)


Remove the tool. Using the mark 'A' on the adjuster, make another mark opposite at 180º (marked 1/2). Half that and mark again at 90º marked 1/4). Half that again and mark at 45º (marked 1/8). This is mark 'B'  below.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/48.jpg)

Replace the tool and breaker bar so that 'A' on the tool aligns with 'A' on the adjuster.  Keep one hand on the socket to ensure it doesnt pop off or move. With one firm movement tighten the bolt until the line on the tool matches up with line 'B' on the adjuster like below
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/49.jpg)

At this stage its a good idea to now check those marks you made on the cam shafts to check that you are timed up correctly. They do move about a bit, but it should be very very obvious if you have it wrong. Again, if you are not sure, take some pics and ask someone.

REASEMBLY

Replace the gasket on the cam chain cover and replace the cover.
Be very carful not to damage anything. Replace the 7 bolts and torque up to 7 ftlbs
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/50.jpg)

Replace the bracket under the cover and clip the loom back in place.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/51.jpg)

Clip the connector back onto the N205 valve
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/52.jpg)
NOTE, the photo above shows an error in the black oval. The plastic loom should run under the metal hard line, not over as in the photo below. The time to sort this out is now.

Replace the cam cover
Remove the old gasket from the cam cover and replace it with a new one. Flip the cam cover over and place on top of the cams. Its a bit tricky as the new gasket will tend to fall off, be patient. Once youve got the cover on, spend a bit of time making sure the the gasket it properly located and sat flat.

Begin to bolt down the cover, just to finger tight.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/53.jpg)

Double check the gasket.

Now torque the bolts up to 7 ftlbs following the sequence below.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/54.jpg)

Remember the 2 bolts for the cambelt cover... again 7 ftlbs
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/55.jpg)

Replace the 2 rear PCV pipes.
The fat one is a pig to get back on but it will go back on. I used a jubilee clip to replace the OEM clip.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/56.jpg)

Replace the front PCV
Remember the smaller hose in the middle of the cam cover.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/57.jpg)

Replace the HPFP. Remembering to reconnect all lines and connectors.
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/58.jpg)

At this stage its worth spending a bit of time with some brake cleaner and towels cleaning under the cam chain cover as you will have spilt oil on the gearbox casing. This is also good practice to monitor for any future oil leaks.

Replace the Battery
(https://daz.co/rich/img/Car%20Stuff/Servicing/Cam%20Chain%20Tensioner/59.jpg)

Replace your Airbox... or Intake system.

Double check that all electrical connectors are connected and the fuel lines are secure on the HPFP.

NOW.... time to take a brave pill and fire the f*cker up!!!!!!


Quick access torque specs....

Cam Adjuster Bolt --------------  Stage 1= 15 ftlbs    Stage 2=  1/8 turn
Cam Chain Tensioner Bolt  ------ 7 ftlbs
Cam Cover Bolts ----------------- 7 ftlbs
Cam Chain Cover ---------------- 7 ftlbs
HPFP Bolts ------------------------ 7 ftlbs

Basically... If in boubt.... 7 ftlbs!  :signLOL:



Good luck!!!!

Rich
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: doylebros on April 11, 2016, 06:36:13 PM
Well as an enthusiastic DIYer Rich you've got as much equipment as a professional,very nice!

I would add a bottle of tipex or a Sharpie marker, aerosol brake cleaner, telescopic mirror magnetic tray, T8 screwdriver,quality light,plenty time and a secure work area as you may need to order bits and be waiting for few days.

I hope the job goes well for you and you enjoy documenting your how to so other may benefit from your efforts.

For me VCDS readings of the relevant group numbers - before and after videos of the job would put your guide ahead of the game with list of postmortem pointers list of what I would do differently if I was doing the job again.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: stuart-88 on April 11, 2016, 06:49:54 PM
Im sure this'll come in handy one day! Hope it all goes well  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 11, 2016, 07:07:11 PM
Cheers guys. Ive got most of those other things doylebros. Doing it on my drive and starting at 9 so fingers crossed I can do it in a day.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: M4T VW on April 11, 2016, 08:03:44 PM
Excellent, Looking forward to this  :party:

FYI, There are two number 8's in the picture  :wink:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: doylebros on April 11, 2016, 08:14:31 PM
Excellent, Looking forward to this  :party:

FYI, There are two number 8's in the picture  :wink:

Go straight to the top of the class this man well done  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 11, 2016, 09:21:27 PM
Ahem......  :stupid:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Leeroy87 on April 11, 2016, 09:24:04 PM
Look forward to this guide  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: M4T VW on April 11, 2016, 09:29:39 PM
Ahem......  :stupid:

Nooo, You didn't have to edit the whole thing. You should have made it 8.5  :grin:

I'm joking. Nice of you to make a guide. I'm looking forward to it  :smiley:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 11, 2016, 09:31:43 PM
LMAO... i should have thought!  :signLOL:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Andy on April 11, 2016, 09:56:42 PM
Cheers guys. Ive got most of those other things doylebros. Doing it on my drive and starting at 9 so fingers crossed I can do it in a day.
hope the weather stays good for you Rich
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: dazza on April 11, 2016, 10:09:04 PM
 :popcornsoda:

Some picks could come in handy maybe a rubber mallet and pry bar.  :evilgrin:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 11, 2016, 10:13:43 PM
Pry bar????  :scared:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: dazza on April 11, 2016, 10:24:27 PM
Pry bar????  :scared:
I used a small pry bar on the rocker cover after it failed to come off with tapping with the rubber mallet.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 11, 2016, 10:37:48 PM
Cool... will see what happens
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 15, 2016, 11:46:52 AM
Bloody hell... Ill still be writing this at christmas!  :signLOL: :signLOL:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: v4rley on April 15, 2016, 11:53:12 AM
Looking good some nice through detail and photos, this is going to be invaluable!

What what the last minute dash for the HPFP o-ring, was it just precautions?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: dazza on April 15, 2016, 11:55:25 AM
What what the last minute dash for the HPFP o-ring, was it just precautions?

I did tell rich to get a HPFP o-ring  :slap:

Bloody hell... Ill still be writing this at christmas!  :signLOL: :signLOL:

Good so far will be worth the effort.  :congrats:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 15, 2016, 12:01:48 PM
For some reason when we came to refit the HPFP the seal had enlarged so it wouldnt fit back in the ridge (like it has stretched). Its never been changed before so for the sake of 13 quid its worth having a spare just incase.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on April 15, 2016, 12:25:58 PM
Nice. Are you going to do the rest of the guide rich? I agree with diylebros I think you should write about vcds values, and remember to put 24/24 for axx and duty cycle for axx fluctuates, but all others are 28/28 and duty cycle sits at 5.9%. Perhaps block 93 put around -2kw. Good write up, going to be the best on the internet.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 15, 2016, 12:37:51 PM
Yes gonna keep doing a bit here and there. Will do some more on it later. But yes it will be as comprehensive as I can make it.

Will speak to you about the values etc ones I've completed it.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 15, 2016, 06:44:41 PM
Guide all done I think. Let me know what you think.


Rich
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: v4rley on April 15, 2016, 07:16:57 PM
Cool. I order a new one today for spares thought it would be a bit cheaper but suppose it's a good bit of rubber.

With your guide is it worth say how to get the cams aligned? Is it turning the bottom crank bolt?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 15, 2016, 07:34:52 PM
Yes... I need to add more regards the timing of the cams. I got lucky as the cams were nearly lined up.

Once ive spoken to alex about the alignment i will add it to the guide.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: doylebros on April 15, 2016, 08:08:11 PM
Rich your attention to detail on this guide will be to the benefit of many others - well done :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: dazza on April 15, 2016, 08:20:05 PM
 :notworthy:

Just make sure the images are not on some crappy photo sharing site it would be a shame to loose them.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: doylebros on April 15, 2016, 08:22:32 PM
:notworthy:

Just make sure the images are not on some crappy photo sharing site it would be a shame to loose them.

Yes a very valid point Dazza :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 15, 2016, 08:33:33 PM
drop box  :smiley:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Paulo P on April 18, 2016, 10:30:38 AM
Great write up there Rich  :congrats: Can I ask how much the VW tools are please?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 18, 2016, 12:50:23 PM
THink they around about 150
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Paulo P on April 18, 2016, 01:25:06 PM
Worthwhile if you're planning on doing a few then, probably not so much if you only plan on doing it once  :sad1:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Lewo on April 18, 2016, 01:57:05 PM
Another great guide write up, trouble is I was lost as soon as you got past opening the bonnet  :ashamed:  :smiley:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 18, 2016, 02:11:13 PM
Another great guide write up, trouble is I was lost as soon as you got past opening the bonnet  :ashamed:  :smiley:


Thanks guys.

I was lost too.... I just loosened a load of bolts and hoped for the best.  :signLOL:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pudding on April 21, 2016, 03:58:36 PM
Really good guide!  You did quite a few common sense things that I failed to do, like marking the cams with a pen etc  :congrats:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on April 21, 2016, 04:08:48 PM
The guide that I followed and I believe Dazza followed as well on vortex was good, but this is much more in depth and comprehensive. I reckon you've probably done a lot of people a big favour here rich, well done for taking the time to do it! :notworthy: :congrats:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on April 22, 2016, 09:10:12 AM
Thanks guys.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: shoaybmakda on April 23, 2016, 02:17:11 AM
excellent write up - would love to have a go at this..my stumbling point currently is i have the AXX engine and my banjo bolt is quite cross threaded which i know if it comes to it is going to be a pain to take out  :doh:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on April 28, 2016, 10:02:45 PM
Thank you for this info and attention to detail, i have these parts on order and will be doing this myself as soon as they arrive  :congrats:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: ChazGTI on May 09, 2016, 05:01:53 PM
Referenced this guide last month and fair play, it's very thorough. Definitely worth the extra effort of removing the battery.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on May 09, 2016, 07:11:47 PM
Yeah you dont wanna drop that last bolt on the cover
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on May 23, 2016, 04:09:19 PM
Ok folks, just stripped down the cam chain cover to find a tenstioner in bits ! also someone has already had a go at this job and the cam adjuster bolt has a very rounded head and i cant get anything on it to remove, can anyone help at all as the tensioner fell to bits and i cant get this back in without removing adjuster, tensioner was glued together  !!! whoever was in this before me needs a slap !
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on May 24, 2016, 01:27:04 AM
Depending on how mangeled the bolt head is... youll either have to try and use the OEM tool. or drill the bolt out
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on May 24, 2016, 05:31:05 AM
Depending on how mangeled the bolt head is... youll either have to try and use the OEM tool. or drill the bolt out

Got the bolt out with the use of a drill, when re-assembling i needed to rotate the intake cam very slightly, when you did it as i notice on your post that your intake cam was in a different position from when you started, did you have to make any adjustment prior to finishing the job? i have a very slight difference between the marks i made on the cams albeit very little.
Thanks in advance
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on May 24, 2016, 08:44:04 AM
Is it all back together @whitemoredooor (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=16119) ?

You can check your timing via VCDS:

Block 91 or in advanced measuring blocks 91-3 & 91-4. These are camshaft adjustment REQUESTED and camshaft adjustment ACTUAL

if AXX - you should see 24KW requested, and +/- 1kw of the requested for actual so 23-25 kw

If BWA and some others (needs checking) - you should see 28KW requested, and +/- 1kw of the requested for actual so 27-29 kw

Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on May 24, 2016, 10:15:47 AM
Providing both cams have rotated by the same amount then it should be fine.

If in doubt turn the engine over twice by hand with a long ratchet on the crank bolt.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on May 24, 2016, 05:53:36 PM
Providing both cams have rotated by the same amount then it should be fine.

If in doubt turn the engine over twice by hand with a long ratchet on the crank bolt.

It's all up and running now, has a bit of a lumpy tick over and with very slight throttle whilst still under 1000rpm it's perfect, spark plugs are looking knackered so will change them tomorrow ,blocked of the pcv while i was at it so going to check there are no leaks there.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 07, 2016, 10:46:20 AM
Ok keep getting camshaft sensor problem now since changing chain and tensioner, clears ok but returns in a day or so?? anyone any ideas ? i have changed the sensor with no change, are there any adaption resets i can do with it being run so long with the buggered chain and tensioner? by that i mean does the cam adjuster adapt to the play in the old chain and tensioner  :thinking:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 07, 2016, 12:34:27 PM
I did think it would adjust itself to suit just not sure, i'm going to poke around today and check wiring etc, thanks
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 07, 2016, 01:37:59 PM
I'm getting this fault, camshaft position correlation which to me means it's not singing of the same hymn sheet as the crankshaft sensor, possibly out a tooth ! i have no misfires car runs lovely and smooth, little judder on tick over but goes away when in gear and foot on brake ( DSG ) so god knows i'm begining to climb walls !!  :doh:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 07, 2016, 03:26:12 PM
Dont have vcds and located in the far north east corner of Scotland.....
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 08, 2016, 10:33:59 AM
I'm putting this down to the timing being out a tooth, does anyone know how to set the inlet cam on these? i had to rotate very slightly to get the cam adjuster back on when i say slight i mean very slight, i didnt think it would be a problem as i had to move it so little. if anyone knows could you let me know how this is done.

Thanks
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: xjay1337 on June 08, 2016, 12:12:55 PM
Buy VCDS


Also Rich owes me 40 miles at 40pence per mile.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 08, 2016, 03:53:28 PM
I will get vcds at some point, just going to strip it down again and sort it out nothing else for it, i have diagnostis and should get kw reading off that so see what i get , thanks
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 08, 2016, 04:17:12 PM
Ok got a reading of 44/45 kw ticking over if the actual should be 24 i would say its a bit out ! anyone have an idea how to adjust the cam? as obviously once the chain is off there is nothing holding it but the locking tool also i don't see any markings on the cam apart from the dimple on the inlet teeth

thanks
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: xjay1337 on June 08, 2016, 04:25:22 PM
Make sure engine is up to operating temp before measuring.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: whitemoredooor on June 08, 2016, 05:14:26 PM
Thats exactly what i did do with regards to cam adjuster and chain, it was minimal turning to the inlet cam to get it on but obviously enough for it to throw it off, car was at temperature when reading was taken
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: tommygti on June 11, 2016, 07:45:21 PM
I'm just in the process of doing this job with the help of this brilliant guide, much appreciated rich . Ive removed the cam cover and cam chain cover and considering the mileage the engine has done (108,000), everything seems to be in good condition. Should I still go ahead and change the tensioner and timing chain? I'm not sure if the previous owner replaced it as there is no record of this in the service history. Would it be advised for a piece of mind as I will be fitting a hybrid K04 in the next month or two.

Here's the condition and a quick video.

(http://daz.co/media/nn193/fiestacossie/IMG_7372_zpsjmmlxrbc.jpg)
http://vid304.photobucket.com/albums/nn193/fiestacossie/IMG_7371_zpsrqdy2dol.mp4
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: xjay1337 on June 14, 2016, 08:51:23 PM
i wouldn't just disassemble it for the sake of it, if you strip it then change it so you might as well  :grin:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: tommygti on June 14, 2016, 09:07:22 PM
i wouldn't just disassemble it for the sake of it, if you strip it then change it so you might as well  :grin:

Very true  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: spacewalker on June 21, 2016, 06:16:13 AM
nice manual ;)
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Juliand on June 23, 2016, 10:37:20 PM
Skipped a few pages, but what a brilliant guide, with great, clear photo's. Invaluable. If I was 10.... no, 20 years younger, I'd happily have a bash at this myself. Seriously very good guide - you will have helped many young bucks to tackle this job. I'm not that confident now, but almost feel as if I could have a go, having looked at this. Very inspiring. Can't think of enough gratifying comments, to justify your efforts. I've bookmarked it, so you never know, ha ha! :thinking: :phew: :wink: :scared:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: ducman77 on August 09, 2016, 07:32:43 PM
Brilliant guide :happy2:
Thank you very much for taking the time and effort to complete it. Very much appreciated!!
Cheers :smiley: :smiley:
Dave
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on August 10, 2016, 12:07:10 AM
No problem. Hope the guide helps.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Atreah on August 24, 2016, 11:26:52 AM
Hey - let me start off by saying how brilliantly this guide is written. Makes me feel as if I could pretty much do it myself, but heck, I'm still gonna leave it to a mechanic by trade who also has the necessary tools to do it.

Anyhow, I'll be getting it done next week or so and I was wondering if anyone on here has any opinions on using aftermarket parts for this job? I definitely gotta do the chain and the tensioner, and was also recommended to do the adjuster "for the sake of it". But the OEM adjuster'll cost me around 400+ quid alone. Seeing that the car is 10 years old, I thought about using a non-oem adjustor, although, considering how vital the part is to the engine, I am a bit hesitant to do so without further research. I could get the non-oem adjuster for around 130-140 quid, so I'm wondering; is it likely for a part like that to just "go to s***", taking the engine with it? Or would I just be facing a faster wear & tear rate with a non-oem part?

I am always a fan of using OEM parts, but considering the age of the car, dishing out 400 + quid for a part that might actually still be completely fine, makes me think about possible alternatives, to say the least.

Thanks in advance for any opinions!
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on February 26, 2017, 01:52:28 AM
I'm doing the cam chain change on my fiends Gti at the moment, and just thought I'd say that a tip for removing the larger rear breather pipe off the back off the rocker cover is if you have an extra pair of hands, is to gently lever the metal section of the breather backwards using a long screwdriver against the engine cover mount whilst the pipe is being worked with a pic from the front of the tube. It came off almost straight away compared to when I did the chain swap on mine without doing it this way.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: superchargedpolo on March 05, 2017, 08:12:53 PM
Very handy and well written guide.
Thanks
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Terry82 on March 25, 2017, 10:08:25 AM
Great write up. Iv read through it a few times now. Think I'll give it a go myself. There's no record of it been done on my gti service history.
 What would all the parts and vw tools cost roughly?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: JamieKirk95 on April 13, 2017, 09:16:19 PM
@Tfsi_Mike (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=293)
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Alex Rhys on July 10, 2017, 06:40:53 AM
This thread saved me a fortune. Thanks Very much!
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Svs on July 15, 2017, 06:49:12 PM
Also before start up when doing any job with cam timing the golden rule turn over twice by hand and check marks if the spot on starts if not time up again this way no nasty surprises
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Ant b on August 18, 2017, 07:53:25 PM
Does anyone fancy doing this for me,really don't want to myself
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: SDARCY118 on September 03, 2017, 04:31:59 PM
Brilliant guide being using this guide as a rough guide to changing my inlet camshaft which has sadly being eaten by the fuel pump :doh:
(only the bolts to take off the cam carrier off as well)...

Thanks :)

Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: v4rley on October 30, 2017, 02:12:21 PM
@rich83 (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=709) can you remove just the chain cover to inspect the condition of the chain without having to remove the cam cover?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on October 30, 2017, 03:04:52 PM
@rich83 (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=709) can you remove just the chain cover to inspect the condition of the chain without having to remove the cam cover?

Yes
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: SDARCY118 on November 19, 2017, 10:07:01 PM
Hi guys,

still having few issues since replacing the inlet camshaft, timing chain and tensioner. the car is currently shaking like mad on idle, misfiring count on cylinders, but it seem's to drive well...

now the only fault code that keeps coming back p000a slow intake response...which would suggest the timing is incorrect but i've checked using the tool with the engine set on bang tdc multiple times now :thinking:, the tool had a little bit of play when placed between the inlet and exhaust camshaft which by looks of things should be correct..

in the last month, i've done the following...
*cleaned oil pick and fresh oil
*replaced the 3 oil separator rings found inside the vvt adjuster
*degreased and cleaned the timing chain cover
*cleaned the n205 valve and also done output test with vcds seemed fine
*compression test results were 160-170psi
*throttle body adaptation
*pcv valve replacement
*dv upgrade to gfb
*tested coil packs and replaced spark plugs

today I managed to check the 91/93 measuring blocks here are the results below...as you can see something still's not right! I'm sure the phase position bank 1 intake shouldn't be as high as 4.0kw...i could be wrong though?!?!

(picture link below sorry can't work out how to get images onto this forum atm)

https://ibb.co/bEE9q6



currently borrowing my university's hex+can cable so i can use vcds on my car but i need to give it back by Wednesday so need some suggestions very quickly.

any help would be much appreciated

sam



Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Terry82 on December 21, 2017, 04:40:42 PM
Great write up.
Whats a rough price on parts for this job?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: l2azvan on May 14, 2018, 02:13:08 PM
Hey - let me start off by saying how brilliantly this guide is written. Makes me feel as if I could pretty much do it myself, but heck, I'm still gonna leave it to a mechanic by trade who also has the necessary tools to do it.

Anyhow, I'll be getting it done next week or so and I was wondering if anyone on here has any opinions on using aftermarket parts for this job? I definitely gotta do the chain and the tensioner, and was also recommended to do the adjuster "for the sake of it". But the OEM adjuster'll cost me around 400+ quid alone. Seeing that the car is 10 years old, I thought about using a non-oem adjustor, although, considering how vital the part is to the engine, I am a bit hesitant to do so without further research. I could get the non-oem adjuster for around 130-140 quid, so I'm wondering; is it likely for a part like that to just "go to s***", taking the engine with it? Or would I just be facing a faster wear & tear rate with a non-oem part?

I am always a fan of using OEM parts, but considering the age of the car, dishing out 400 + quid for a part that might actually still be completely fine, makes me think about possible alternatives, to say the least.

Thanks in advance for any opinions!

Found myself in the same position, any thoughts ?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on June 15, 2018, 03:47:12 PM
Hi All,

A question for the knowers and a reply for parts rough prices - hope this helps and you can help me.

I'm doing this job tomorrow along with the cambelt & water pump. I will be using this guide, so thanks Rich! I'm sure... i am one of many to use this guide.
Price guide for all parts (Geniune VW) i paid just under£300 - BUT i did get a small discount through my mate. So i would imagine you'd be looking around the £200 mark from TPS for chain and tensioner, gaskets, bolts etc.
i have brought OEM cam locking tools and adjuster socket, but just found out i can borrow them from a mate at Audi so will have both sets to hand.
I'm a little confused as to how the tolerances of the inlet cam or both cams can be out? If you are removing the old chain and replacing it with the new and having to adjust the inlet cam the most tiniest bit (as in not a tooth/link out of timing) how can the tolerances be out? am i right in thinking the timing cannot be adjusted afterwards? just a little confused, as surely if the same amount of links meet the same teeth then surely those no adjustment? i will be marking the cams etc and hope the cams wont move, but after reading... i know they will - hence ill mark up well.
in a nut shell - is there any adjustment that can me made to the inlet cam if it does decide to end up slightly off once new chain is on? i don't think so but thought id ask.
thanks in advance.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: mcdoof on July 09, 2018, 01:27:35 AM
Hey - let me start off by saying how brilliantly this guide is written. Makes me feel as if I could pretty much do it myself, but heck, I'm still gonna leave it to a mechanic by trade who also has the necessary tools to do it.

Anyhow, I'll be getting it done next week or so and I was wondering if anyone on here has any opinions on using aftermarket parts for this job? I definitely gotta do the chain and the tensioner, and was also recommended to do the adjuster "for the sake of it". But the OEM adjuster'll cost me around 400+ quid alone. Seeing that the car is 10 years old, I thought about using a non-oem adjustor, although, considering how vital the part is to the engine, I am a bit hesitant to do so without further research. I could get the non-oem adjuster for around 130-140 quid, so I'm wondering; is it likely for a part like that to just "go to s***", taking the engine with it? Or would I just be facing a faster wear & tear rate with a non-oem part?

I am always a fan of using OEM parts, but considering the age of the car, dishing out 400 + quid for a part that might actually still be completely fine, makes me think about possible alternatives, to say the least.

Thanks in advance for any opinions!

Found myself in the same position, any thoughts ?

I'm in the same boat. Plus there are so many different aftermarket parts. Anyone have some direction on what would be good?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: LeBlaaanc on September 30, 2018, 09:41:31 PM
Any tips getting this off if your tool and bolt rounded out? I’ve built a jig and drilled 3/16 bit through it and hammered a T55 on it and no dice (i understand the head of a bolt give it its holding force). I’m fresh out of ideas, was going to try to drill a slot in it or something. Any help is appreciated.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: warpigroadkill on October 23, 2018, 10:57:53 AM
Thank you for making this guide. I've just done this to my car and it's made a massive difference to the sound of the engine. It's much more quieter and smoother running. I bought a FSi 2.0 timing tool kit from eBay for about £30 and that wasn't worth the money. I ended up going to VW and buying the correct cam holding tool, the correct socket for the exhaust cam bolt, and the lever for the intake cam. These are listed in your initial post, so look there for the part numbers.

Very easy job. I never removed the two PCV pipes at the back of the rocker cover (near the turbo). They were being a pain so I proped up the cover with a piece of wood. That gives you more than enough room to set the cam timing tool in position and do the timing chain/tensioner etc. So don't go breaking those pipes.

The gasket for the rocker cover was very brittle. I covered the open cams and removed the old gasket with a screwdriver, CAREFULLY! Don't break the plastic valve cover.
I searched around for timing belt kits etc and found that the genuine VW parts from the dealership was the cheapest.

After completing this fix and testing to make sure it works, I've followed it up with some CRC intake valve cleaner, oil and plug change and the car runs like a beaut. Doesn't sound like a diesel tank anymore  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: vojtechson on February 28, 2019, 03:01:11 PM
Can you guys see any photos on the first page? I wanted to print this guide out, but for some reason, the photos dissapeared ?!?!
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: dazza on February 28, 2019, 11:25:54 PM
should be fixed now.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: GTIdownunder on June 14, 2019, 01:30:43 PM
What would you suggest if you have sheared the polydrive bolt... asking for a friend...
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on June 14, 2019, 05:12:18 PM
What would you suggest if you have sheared the polydrive bolt... asking for a friend...
Drill it.. Tap and die! You only need to drill in far enough to crack the cone of the bolt and then the thread virtually spins out free.. just be careful and make sure you drill it in the dead centre. Sucking eggs and all that


Sent from my iPhone using Tapatalk
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on June 17, 2019, 10:26:46 AM
I'd probably have a hoover running next to the spinning bit to minimise shrapnel
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on June 17, 2019, 10:46:21 AM
I'd probably have a hoover running next to the spinning bit to minimise shrapnel
Yes, brilliant idea. I had tissue underneath and you can bet your bottom dollar a few bits fell on top of the gearbox


Sent from my iPhone using Tapatalk
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pesky jones on June 17, 2019, 12:16:15 PM
TBH I was thinking more about metal inside the head/cam chain area.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on June 17, 2019, 12:17:33 PM
TBH I was thinking more about metal inside the head/cam chain area.
It sure is a valid point. From what I remember, a lot of it just falls down away from the delicate bits. But a precaution is always best!


Sent from my iPhone using Tapatalk
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: svvg on September 01, 2019, 09:52:56 PM
Excellent guide - but a couple of things missing which I’m a bit confused about and would be grateful for some help with.

Once the adjuster bolt is cracked loose - why do you remove the bolt with a different tool? (The guide refers to tool T10020?).

And how do you adjust to timing if it's out - is it by turning the crank bolt with a breaker bar?

And finally, can the intake and exhaust cams be moved independently? I’ve done the timing on an old Peugeot and also on a couple of bmws, and the bmws have a clutch type arrangement which allow each cam to be turned independently and then locked.

Many thanks!!
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on September 02, 2019, 09:54:46 AM
Excellent guide - but a couple of things missing which I’m a bit confused about and would be grateful for some help with.

Once the adjuster bolt is cracked loose - why do you remove the bolt with a different tool? (The guide refers to tool T10020?).

And how do you adjust to timing if it's out - is it by turning the crank bolt with a breaker bar?

And finally, can the intake and exhaust cams be moved independently? I’ve done the timing on an old Peugeot and also on a couple of bmws, and the bmws have a clutch type arrangement which allow each cam to be turned independently and then locked.

Many thanks!!
Hi mate,
Done this job myself a few times for myself and others. Unless I’ve missed something here in the guide you don’t have to use a different tool to remove the cam adjuster bolt?? You need to use T40080 to crack the bolt and then use the same socket to extract the bolt (top tip: ONLY use the genuine T40080 from TPS/VW) don’t be trying that Laser or any aftermarket copy! They are crap and shatter! Trust me it happened to me the first time and I split my thumb wide open at breaking point!
The cams are semi independent as it’s the chain that links them, so once the chain is removed the intake cam can roll but the exhaust cam is a little sturdier as it’s still linked to the crank via the cam belt. Assuming you’ll be using the correct cam locking tool? Otherwise I really don’t think you’ll be able to crack that cam adjuster bolt? Someone would have found a way but I wouldn’t recommend. I found there’s no decent (if any) timing marks for the cams. Once the cambelt side is perfectly lined up you know the exhaust cam is lined up so it’s just a matter of lining the inlet cam. I found even with the cam locking tool.. (T10252) the inlet cam rolls back 1 tooth once the chain and adjuster is removed because the locking tool still allows the cams to rolls slightly, so once you’ve positioned the exhaust cam again via cambelt side the inlet is 1 tooth back and held there by the valves. But a good lining up I found is to dead set your cambelt timing (crank mark etc) then look directly at the cam shafts end from the chain side and look at the the second set of cam lobes away from you. Once done they should be pointing up and towards each other. So the inlet cam lobe will be 1 o’clock and the exhaust cam will be 11 o’clock. Once the cambelt is timed then the exhaust cam lobe should be at 11 o’clock (or there abouts) that’s when T10020 comes into play to pull the inlet cam to where it needs to be for when putting the chain on (1 o’clock). I too followed Rich’s guide and it’s a great guide, wouldn’t have learned without it! silly me tho didn’t mark up my cams with pen because I thought the locking tool would be perfect lol that’s how I learnt the hard way. If you can get your head around all my waffle above and digest it, you “should” be fine haha.
No clutch type arrangements on these cams I’m afraid. (Be sure to line the dowel at the back of the cam adjuster into the cam on the exhaust cam too)
Good luck. Plenty of help and advise from the forum if needed :-)


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Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: svvg on September 02, 2019, 10:22:52 AM
Thanks for that - really helpful.

Yes - I’ve seen a few horror stories re shattered adjuster sockets (the Laser ones and other “equivalents”) and would always want genuine tools for timing jobs - but starts to make it not cost effective if I have to buy the tools vs pay the labour... Can’t seem to find anyone selling or renting used, but genuine,  tools on ebay so will price them up. Guess I could sell them afterwards actually....

“Only” other issue is that I’m a bit worried about shearing the head off the adjuster bolt, even with the correct socket - as really don’t fancy trying to drill it out!!! Not sure if fear will get the better of me!

Car sounds diesely on start up and then quietens down after a minute or so - and it judders a LOT too - but again settles down after a minute or two, so (after some feedback on here) I think it might be the oil pressure in the cam chain tensioner taking a while to build up?  When it’s warm it’s fine...

Thanks for feedback. Very much appreciated - and. I hope to contribute something back once I’m a bit more up to speed on these cars. (I’m all over the AGG mk3 8valve golf gti if that helps - and BMWs...!).

Thanks again.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on September 02, 2019, 10:34:12 AM
Thanks for that - really helpful.

Yes - I’ve seen a few horror stories re shattered adjuster sockets (the Laser ones and other “equivalents”) and would always want genuine tools for timing jobs - but starts to make it not cost effective if I have to buy the tools vs pay the labour... Can’t seem to find anyone selling or renting used, but genuine,  tools on ebay so will price them up. Guess I could sell them afterwards actually....

“Only” other issue is that I’m a bit worried about shearing the head off the adjuster bolt, even with the correct socket - as really don’t fancy trying to drill it out!!! Not sure if fear will get the better of me!

Car sounds diesely on start up and then quietens down after a minute or so - and it judders a LOT too - but again settles down after a minute or two, so (after some feedback on here) I think it might be the oil pressure in the cam chain tensioner taking a while to build up?  When it’s warm it’s fine...

Thanks for feedback. Very much appreciated - and. I hope to contribute something back once I’m a bit more up to speed on these cars. (I’m all over the AGG mk3 8valve golf gti if that helps - and BMWs...!).

Thanks again.
It could be the issue to do with the juddering etc, but I wouldn’t be so convinced myself. If your mileage is high and chains never been done it’ll be worth doing as a preventative.
If you go TPS and buy the socket just quote the T number. And then you can get the locking tool and cam movement tool all in a kit for about £30 on eBay. The locking tool works perfect, I have used both the genuine locking tool and the one from eBay I do really rate it mate. So realistically the “special tools” are only £40 for keeps.
Don’t scare yourself with that bolt! First time I did it... after shattering my cheap laser socket and then using a ribe bit (which wasn’t deep enough) I managed to wreck my bolt, so drilled it out! It’s actually quite easy, once the cone of the bolt is cracked the thread will just spin out!
Only after getting my timing wrong the first time (Inlet cam out 1 tooth) I then brought the genuine socket and has stood the test of time.. a good few times now!


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Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: svvg on September 02, 2019, 12:32:37 PM
Thanks very much - £40 for the tools sounds like a bargain. So VW genuine adjuster bolt socket, and ebay for the cam locking tool? Would you mind recommending which one to go for?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: muff1991 on September 02, 2019, 12:37:32 PM
Thanks very much - £40 for the tools sounds like a bargain. So VW genuine adjuster bolt socket, and ebay for the cam locking tool? Would you mind recommending which one to go for?
100% genuine adjuster bolt socket (can source from TPS - mine was like £7 ish)
eBay for the rest, The listing has changed.. but this is the kinda kit I got: https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F262211307586
:-)


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Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: svvg on September 02, 2019, 12:54:27 PM
Thanks!  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: maxamplitude10 on January 12, 2020, 08:34:10 PM
How often should this be changed?
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: f00glee on January 13, 2020, 08:21:07 AM
How often should this be changed?

No official interval or even a recognised sensible time. It's more a case of the chain and tensioner start making a racket over time; at the point it annoys the owner enough - its time to do it.

I'm reliably told they don't tend to break on the mk5, just make a noise. Its the mk6 with a totally different set up which is the main culprit for snapping chains and I reckon a lot of the horror stories of chains snapping on GTIs around 2011/12 onward has back filtered into the mk5 community.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: maxamplitude10 on January 13, 2020, 10:08:52 AM
Ok I'll have a listen to mine then its on 111k at the mo but seems to have been looked after when I changed the HPFP piston it was like brand new:-)

Thanks F00gle
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: brian_badonde on March 12, 2020, 10:11:05 AM
@rich83 (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=709) I did this job a couple of weeks ago and wanted to say thank you for your excellent DIY - doubt I'd have managed without. Can't believe how much better the engine sounds now, all I can hear is the injectors and fuel pump firing. No more tractor noises at idle any more...

The only comment I have is that I could not rotate the engine from the inlet cam lobe - the T10020 tool just started bending and I didn't want to force anything. In the end I rotated the engine from the main crank pulley accessed through the driver's side wheel well.

The chain itself didn't have any signs of stretch, but I replaced it anyway. The tensioner on the other hand was still intact but definitely on its way out. The top plastic wear plate had a hairline crack running through the middle and the bottom plate was heavily worn from the chain. If you're like me and at ~120,000 miles and it hasn't been done before, I would seriously consider getting it done.
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: rich83 on March 12, 2020, 06:24:37 PM
No problem.


Yes thats an error with the guide... the engine needs to be rotated via the crank shaft.  :happy2:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: hoon98 on May 26, 2020, 11:08:02 PM
Just finished this!! Thanks so much for the guide, it was invaluable in getting the job done and saved a tonne of money!!  :happy2:

Wasn't without its issues though... First thing that went wrong was when manouvering the coolant lines... a nipple on one of the plastic flanges broke off showering me and the engine bay in coolant!

Secondly despite being careful I managed to strip the Adjuster bolt when trying to undo it... Bit of a nightmare, had to drill it a bit to relieve some of the torque before opening it with a spline hammered in to it...

Got there eventually though!  :doh:
Title: Re: DIY - Cam Chain and Tensioner Guide
Post by: Pudding on July 10, 2020, 05:49:00 PM
You really need someone to push hard on the breaker bar whilst you undo it, or use a decent cordless impact wrench if working solo  :happy2: