Removing camshaft timing chains from camshafts: VW Phaeton (BAR, BMK, CARA, CEXA, …)

🧭 Before you start

Fits: VW Phaeton (3D)

• Opens: coolant
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T40060, locking pin, torque wrench
• Renewed: gaskets

Don't miss

• In order to prevent damage to the intake manifold flap motor V157, the connecting rod is not removed.
• Cover chain tensioner opening with a cloth or similar to stop small parts dropping in.
• Screw in two bolts (2) for chain sprocket, but do not tighten bolts.
• The crankshaft must only be turned in engine direction of rotation. — Turn crankshaft two rotations in normal direction of rotation (arrow) until the crankshaft is just before TDC again.
• Screw plug (arrow) for TDC mark into upper part of sump with a new seal.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Drain coolant .
2. Remove vacuum pump .
3. Remove air mass sensor/turbocharger connection hose.
4. Unbolt engine lifting eye (arrow) from cylinder head.
5. Remove air intake hose together with crankcase breather hose (arrows).

6. Separate connector (3) at intake manifold flap motor V157.
7. Remove bolts (2) and (4) and move intake manifold flap motor V157 clear to the side (with connecting rod installed). [Note: In order to prevent damage to the intake manifold flap motor V157, the connecting rod is not removed.]
8. Separate connector (1) at coolant temperature sender G62.
9. Remove bolt (2).
10. Disconnect coolant hoses (arrows) and take out coolant pipe (rear).
11. Unscrew bolts (1 … 4) and remove left timing chain cover.
12. Unscrew bolts (1 … 4) and remove right timing chain cover.
13. Insert guide pin of adapter T40058 so that the large diameter (arrow 1) points towards the engine. The smaller diameter (arrow 2) faces the adapter.
14. Using adapter T40058 turn the crankshaft in the normal direction of rotation (arrow) to TDC. [Note: The locking pin T40060 has a flat (2) which makes it easier to insert when the locating bores in the camshaft and cylinder head are not exactly in line.The locking pin is inserted initially so that the side pin (1) is perpendicular to the imaginary line between the locking pin and the centre of the camshaft.To obtain the correct TDC position, the side pin (1) must then be turned 90° (arrow) so it is in line with the imaginary line between the locking pin and the centre of the camshaft.]
15. Check that camshafts on both cylinder heads are positioned at TDC.
16. Lay a cloth under upper part of sump to catch engine oil.
17. Unscrew plug (arrow) from upper part of sump.
18. ⚠ To avoid any risk of injury, do not rotate crankshaft while feeling for TDC hole with your finger. — Screw locking pin3242 into threaded hole (20 Nm); if necessary, turn crankshaft (1) backwards and forwards slightly to fully centralise locking pin. — 20 Nm (15 lb-ft)
19. Press guide rail of chain tensioner for left timing chain in direction of arrow and lock chain tensioner by inserting a 3.3 mm ∅ drill bit (Item 1).
20. Unscrew bolts (1) from chain tensioner and (2) from camshaft chain sprocket.
21. Remove camshaft chain sprocket and left chain tensioner. [Note: Cover chain tensioner opening with a cloth or similar to stop small parts dropping in.]
22. Press guide rail of chain tensioner for right timing chain in direction of arrow and lock chain tensioner by inserting a 3.3 mm ∅ drill bit (Item 1).
23. Unscrew bolts (1) from chain tensioner and (2) from camshaft chain sprocket.
24. Remove camshaft chain sprocket and right chain tensioner. [Note: Cover chain tensioner opening with a cloth or similar to stop small parts dropping in.] [Note: Renew gaskets, seals and O-rings.Renew the bolts tightened with specified tightening angle.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with hose clips (same as original equipment) Parts catalogue.The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Danger of damage to valves and piston crowns.]
25. Check that camshafts on both cylinder heads are positioned at TDC.
26. Remove locking pins T40060 from both camshafts. [Note: If the locking pins cannot be inserted in the camshafts, the camshafts can be turned slightly using adapter T40061. To do so, screw securing bolts for camshaft chain sprocket into camshaft.The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Danger of damage to valves and piston crowns.]
27. Install left timing chain with camshaft chain sprocket and chain tensioner.
28. Tighten bolts (1) for chain tensioner.
29. Screw in two bolts (2) for chain sprocket, but do not tighten bolts.
30. Lock left camshaft with locking pin T40060.
31. Pull drill bit (3) from locating hole, this releases the left chain tensioner.
32. Install right timing chain with camshaft chain sprocket and chain tensioner.
33. Tighten bolts (1) for chain tensioner.
34. Screw in two bolts (2) for chain sprocket, but do not tighten bolts.
35. Lock right camshaft with locking pin T40060.
36. Pull drill bit (3) out of locating hole; this releases the right chain tensioner.
37. Apply a torque of 30 Nm to right camshaft chain sprocket in direction of arrow using a torque wrench and adapter T40062. Maintain this torque for the following step. — 30 Nm (22 lb-ft)
38. Tighten bolts (1) and (2).
39. Take off adapter T40062 and pull out locking pin T40060.
40. Tighten remaining bolts for right chain sprocket.
41. Using a torque wrench and adapter T40062, apply a torque of 15 Nm to left chain sprocket in (direction of arrow) and maintain pre-tension. — 15 Nm (11 lb-ft)
42. Tighten bolts (1) and (2).
43. Take off adapter T40062 and pull out locking pin T40060.
44. Tighten remaining bolts for left chain sprocket.
45. Remove locking pin3242.
46. ⚠ The crankshaft must only be turned in engine direction of rotation. — Turn crankshaft two rotations in normal direction of rotation (arrow) until the crankshaft is just before TDC again.
47. While turning in this direction, lock crankshaft (1) with locking pin3242. Tighten locking pin to 20 Nm. — 20 Nm (15 lb-ft)
48. ⚠ If the crankshaft has been rotated even only slightly beyond the TDC position, turn it back approx. 10° so you can then reset it to TDC by turning in the normal direction of rotation. — Check that it is now possible to lock the camshafts with locking pins T40060.
49. Loosen all bolts (arrows) on the relevant chain sprocket approx. 1 turn.
50. Apply adapter T40061 to the heads of the loosened bolts.
51. Turn camshaft slightly backwards and forwards with adapter T40061 until locking pin T40060 can be inserted.
52. With adapter T40061 and adjustment pin T40060 still in position, tighten bolts on chain sprocket to approx: 5 Nm. — 5 Nm (3.7 lb-ft)
53. Remove adjustment pin T40060 and adapter T40061.
54. Tighten bolts on chain sprocket to final torque.
55. Repeat this procedure on the other cylinder bank if necessary.
56. Remove locking pin3242.
57. Check valve timing once again .
58. Screw plug (arrow) for TDC mark into upper part of sump with a new seal.
59. Install timing chain covers .
60. Install rear coolant pipe.

Other VW procedures

• Removing and installing oil cooler – Audi A3
• Removing and installing intake manifold (bottom section) with fuel rail · 1 torque figures
• Removing and installing coolant temperature sender G62 – VW · 1 torque figures
• Removing and installing drive chain for valve gear – VW
• Removing and installing drive chain for auxiliary drives · 1 torque figures
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures