Subject: 2.0L Chain Drive - Cam/Crank correlation check - - - - - > Updated December 2018 - New Photos!
Here is a quick tip for checking the Audi/Volkswagen 2.0L chain drive engines for proper camshafts to crankshaft timing.
- There are known chain tensioner failures, see -- > How The 2.0T TSI Timing Chain Tensioner Fails
1) Verify the number 1 piston is at TDC - (Top Dead Center). You will want to remove the #1 spark plug and verify the piston is all the way up, because the timing marks on the balance/cover could be off. - Yes it is possible to complete a repair without the special timing tools on the first try, I have personally done it, however, the special timing tools will help you so that you do not have to do the job twice.
Note: There is a paint mark at the 12 o'clock position of the crank pulley and a grove at about the 4 o'clock position.
- The timing chain cover has two marks, one at 12 o'clock and one at 4 o'clock, make sure you correctly set these marks, see by the pictures below!
These are 12 o'clock marks on the crankshaft pulley
See the example, click on the picture here --->
4 o'clock marks on the crankshaft pulley
See the example, click on the picture here --->
- The pictures here shows the crank timing gear(top/bottom side), notice the design, it is possible the parts could mesh together incorrectly during installation, after a repair.
and 
2) Next, remove top camshaft gear cover, front of the engine.
3) Using a dial or digital caliper tool that will measure in millimeters, measure the distance between the top Timing Chain Guide mount 1 and the Intake Cam mark 2.
Specification is 61 to 64mm
See the example, click on the picture here --->
4) Using a dial or digital caliper tool that will measure in millimeters, measure the distance between the Exhaust Cam mark 3 and the Intake Cam mark 2 .
Specification is 124 to 126mm
See the example, click on the picture here --->
- If the readings are off, suspect there is a concern with the cam/crank timing, typically there should be a fault code for this condition, such as a 16400/P0016/000022 - Bank 1: Camshaft Position Sensor (G40) / Engine Speed Sensor (G28): Incorrect Correlation .
- Also if there was no prior repairs to this engine, it is possible there is a bigger problem awaiting and immediate attention may be required. Yes, that is a broken intake valve, #3 piston, all the intake valves were bent!.
Ask me how I know this....
-- oh, and there is the 'might as well' factor. . . when and if you have this all apart, check the 'Camshaft Bridge' (part that sends oil to the camshafts), the screen inside can fail and the material can migrate to the cam bearings, possibly damaging the cylinder head.
ref: VW Tech Tip "01-15-08 MIL ON, DTC(s) P0011, P0016, P000A, P0341 and or P052A Stored in ECM Fault Memory"
Camshaft Adjuster Valve - FAILED (The center part should NOT be extended out as seen in these photos!) Dec.2018
Hope this helps,
drpeter
Here is a quick tip for checking the Audi/Volkswagen 2.0L chain drive engines for proper camshafts to crankshaft timing.
- There are known chain tensioner failures, see -- > How The 2.0T TSI Timing Chain Tensioner Fails
1) Verify the number 1 piston is at TDC - (Top Dead Center). You will want to remove the #1 spark plug and verify the piston is all the way up, because the timing marks on the balance/cover could be off. - Yes it is possible to complete a repair without the special timing tools on the first try, I have personally done it, however, the special timing tools will help you so that you do not have to do the job twice.
Note: There is a paint mark at the 12 o'clock position of the crank pulley and a grove at about the 4 o'clock position.
- The timing chain cover has two marks, one at 12 o'clock and one at 4 o'clock, make sure you correctly set these marks, see by the pictures below!
These are 12 o'clock marks on the crankshaft pulley
See the example, click on the picture here --->
4 o'clock marks on the crankshaft pulley
See the example, click on the picture here --->
- The pictures here shows the crank timing gear(top/bottom side), notice the design, it is possible the parts could mesh together incorrectly during installation, after a repair.
and 
2) Next, remove top camshaft gear cover, front of the engine.
3) Using a dial or digital caliper tool that will measure in millimeters, measure the distance between the top Timing Chain Guide mount 1 and the Intake Cam mark 2.
Specification is 61 to 64mm
See the example, click on the picture here --->
4) Using a dial or digital caliper tool that will measure in millimeters, measure the distance between the Exhaust Cam mark 3 and the Intake Cam mark 2 .
Specification is 124 to 126mm
See the example, click on the picture here --->
- If the readings are off, suspect there is a concern with the cam/crank timing, typically there should be a fault code for this condition, such as a 16400/P0016/000022 - Bank 1: Camshaft Position Sensor (G40) / Engine Speed Sensor (G28): Incorrect Correlation .
- Also if there was no prior repairs to this engine, it is possible there is a bigger problem awaiting and immediate attention may be required. Yes, that is a broken intake valve, #3 piston, all the intake valves were bent!.
Ask me how I know this....
-- oh, and there is the 'might as well' factor. . . when and if you have this all apart, check the 'Camshaft Bridge' (part that sends oil to the camshafts), the screen inside can fail and the material can migrate to the cam bearings, possibly damaging the cylinder head.
ref: VW Tech Tip "01-15-08 MIL ON, DTC(s) P0011, P0016, P000A, P0341 and or P052A Stored in ECM Fault Memory"
Camshaft Adjuster Valve - FAILED (The center part should NOT be extended out as seen in these photos!) Dec.2018
Hope this helps,
drpeter
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