How-to: 1.8T Cam Chain Tensioner Gasket replacement

[Matt Devo]

skill: 4/10
time: 1 hr
part(s): CCT gasket, OEM part # 058 198 217.
special tools: Cam Chain Tensioner Compressor tool (OE tool # 3366)
cost: ~$25 for gasket set + tool + sealant

It is recommended to do this at the same time you change the valve cover gasket, since you need to remove the VC gasket to replace the CCT gasket.

old gasket set + tool:



new gasket set (color of half-moon piece may vary - mine was creme):




The operating area: (VC gasket already removed)



start: remove valve cover and VC gasket. This tech article on AW is a pretty good reference.

Once the VC and gasket are removed, ensure that the piston on the CC tensioner is fully extended (see pic). If not, or if you're not sure, use the bolt on the lower crankshaft damper and rotate *clockwise* until you hit TDC.

CCT piston: (pic courtesy of 'junkie1.8TQ' on AZ)



Install the CCT compressor tool. Be 100% sure that the bolt is perpendicular to the block when tightening to prevent cross-threading (thx Dave U.). Tighten with a ratchet until resistance is met. There should be a bit of slack in the chain now. Bolt in tool is 5mm? hex.

CCT Compressor tool use: (pic courtesy of 'junkie1.8TQ' on AZ)



Next, remove the 4 torx bolts (T27?) holding the tensioner to the block:



Once the bolts are removed, the tensioner assembly can be lifted up, creating just enough space for the old gasket and half-moon to be removed. They may be stuck, so be prepared with a flat head screwdriver. The gasket can be most easily slid out the left side, and the half-moon out the back (towards firewall)

When installing the new gasket, it is recommended to put a light coat of sealant on the top side of the lower right corner (see pic).



my preferred sealant:



Now, reinstall the 4 torx bolts, screwing in each a bit at a time to keep even pressure on the tensioner as you reinstall. Remove the CCT compressor tool. Install VC gasket, applying a small amount of sealant at the points shown:



Put VC back on, installation is the reverse of removal. If the underside of your VC doesn't look nice and clean, you may want to do a cycle or two of Auto-RX.

Underside of my VC at 133k miles. Note I had replaced my VC gasket around 100k, and did an Auto-RX treatment at that time.



Lastly, sit back and crack open a cold one, and bask in the self-satisfaction of having saved a few hundred dollars at the dealer =)

[old guy]

Excellent job Matt! Rep to you!!

[actlsub9]

Post it in here and I'll put it in the DIY section.

[dougyfresh]

i [heart] hylomar


nice write-up.

[Matt Devo]

Post it in here and I'll put it in the DIY section.

it's posted in the DIY section, awaiting admin approval

[HIERLEVELZ]

Who sells the tool? I changed my vc gasket but couldnt change the cct gasket because I didnt have the tool or the know how.

[Matt Devo]

Who sells the tool? I changed my vc gasket but couldnt change the cct gasket because I didnt have the tool or the know how.

3366 here: http://buy.equipmentsolutions.com/login/login.aspx

[jonan]

3366 here: http://buy.equipmentsolutions.com/login/login.aspx

that's where i got mine, give them

[HIERLEVELZ]

thanks

that's where i got mine, give them

[xccess]

I posted this in the DIY section but it's not approved yet, I'll update the link when it is. In the mean time, here's a link to the same writeup posted on "that other site"

http://forums.quattroworld.com/a4b6/msgs/1759.phtml

I am try to figure out where is the half moon in this picture since I will have to do my soon on 2.7t, where is your locate exactly

[AvanTTix]

it's posted in the DIY section, awaiting admin approval

Matt, just post it here. Anthony has been quite busy w/ other projects lately, and I'm sure people would love to see your DIY here on AZ. I know I do...

[mdzaudi]

Anyone know where to get the cam chain tensioner compressor tool (OE tool #3366)? I'm not finding it on ECS and i certainly don't want to buy from the dealer.

[Matt Devo]

Anyone know where to get the cam chain tensioner compressor tool (OE tool #3366)? I'm not finding it on ECS and i certainly don't want to buy from the dealer.

5 posts up....

[mdzaudi]

5 posts up....

Well don't i feel dumb.

[a4wd]

READ!!

[mdzaudi]

READ!!

I did the first time but obviously too quickly

[Wholsea]

Here is where you put the half moon...


Just replaced mine this weekend... Actually replaced the entire CCT. Wasn't that bad.

Take note of when they say "do not over tighten" MY CCT Tool busted one of the posts off the back side of the CCT and I had to use a C-Clamp to finish the job.

Used this DIY along with the one posted here
http://www.passatworld.com/forums/sh...d.php?t=215732

[Scott Evil]

Here is where you put the half moon...


Just replaced mine this weekend... Actually replaced the entire CCT. Wasn't that bad.

Take note of when they say "do not over tighten" MY CCT Tool busted one of the posts off the back side of the CCT and I had to use a C-Clamp to finish the job.

Used this DIY along with the one posted here
http://www.passatworld.com/forums/sh...d.php?t=215732

Now my hand is on the interweb! LOL!

[Scott Evil]

I am try to figure out where is the half moon in this picture since I will have to do my soon on 2.7t, where is your locate exactly

it goes where the //////'s box is.

[BARRY]

it goes where the //////'s box is.

its under that box. you see a half circle under it? its right there.

[rccks96]

FYI - the special tool isn't necessary. Mine broke when I was screwing it in (damn that thing is weak). But by simply unscrewing the CCT - I still had enough room to replace the gaskets.

[SilvA4Q]

i did this probably a month or two ago and now im having a slight leak coming out of the back of the valve cover. it seems to be coming from the half moon that is part of the valve cover gasket. i'll have to admit that i didnt change the cct gasket or the lone half moon but that was because i couldnt get the camshaft sprocket to turn. it wouldnt go counter clockwise, am I missing something? does the car need to be in N to do this? and what did i do wrong to make the valve cover not sit properly where the attached half moon is?

[rccks96]

i did this probably a month or two ago and now im having a slight leak coming out of the back of the valve cover. it seems to be coming from the half moon that is part of the valve cover gasket. i'll have to admit that i didnt change the cct gasket or the lone half moon but that was because i couldnt get the camshaft sprocket to turn. it wouldnt go counter clockwise, am I missing something? does the car need to be in N to do this? and what did i do wrong to make the valve cover not sit properly where the attached half moon is?

The main culprit of my leak was the half moon of the CCT gasket. So yes, I would definitely recommend changing that.

btw, you don't turn the camshaft counter clockwise, you turn it clockwise. I had the car in neutral when i did it, though I'm not sure that really did much. It was pretty hard to turn as well.

[SilvA4Q]

thanks for the info, the oil seems to be leaking from the half moon of the vcg though. its located in the back left (passenger side) portion of the valve cover. was i supposed to line the entire back portion of the valved cover with sealant, especially the half moon portion of he vcg, to get it to seal right? i thought it was just a couple spots.

[Sales@RAI]

thanks for the info, the oil seems to be leaking from the half moon of the vcg though. its located in the back left (passenger side) portion of the valve cover. was i supposed to line the entire back portion of the valved cover with sealant, especially the half moon portion of he vcg, to get it to seal right? i thought it was just a couple spots.

it's wherever there is an edge. There are 2 possible things that went wrong for you

1. You didn't tighten the VC nuts down correctly
2. Your VC is defective

[SilvA4Q]

i dont think it was my tightening of the vc that did it. i did the criss-cross tightening and everywhere else along the edge it has held up perfectly and there are no leaks, its just at the spot where the half moon portion of the vcg is that oil is seeping out from under the half moon. when you said edge, do you mean corner? ultimately, my question is did you put sealant on the portion where the half moon sits in the rear left (passenger side) of the valve cover gasket lays?

and would it be a good idea to put a little sealant in that gap in mean time until i get a chance to do the vcg and cct gasket again?

[rccks96]

I didn't put any sealant in the half moon areas. Just the edges where on the back - the CCT meets the engine block, and in the front where theres a joint as well (not sure what's sitting on the engine there).

[doublezero30]

Bumping an old thread here. First off great writeup matt. My question:

i just got back from getting my coilpack recall done and they told me the cam tensioner seal is starting to leak. Is this the same as what this writeup is about? Thanks

[Matt Devo]

Bumping an old thread here. First off great writeup matt. My question:

i just got back from getting my coilpack recall done and they told me the cam tensioner seal is starting to leak. Is this the same as what this writeup is about? Thanks

yup

[doublezero30]

sweet thanks! i will be doing this shortly! bookmarked.

[mcpath]

Matt your the man.

[doublezero30]

doing this today.....

to find the top most point i just turn the camshaft clockwise until it wont go any farther? thanks

[Matt Devo]

doing this today.....

to find the top most point i just turn the camshaft clockwise until it wont go any farther? thanks

well as you turn it becomes more difficult, until you hit TDC. After that point, it will get real easy and if you go too far you'll just have to keep turning until you're back at the top

[n7plus1]

its pretty much a son of a bitch...but i followed this great guide :)

[Doctor]

I tried to change the tensioner's gasket today but when i tried to reach the Upper point and allign the arrows with the marks, and tried to turn the crankshaft with the 16mm tool, i just couldnt turn it...i think the compression was there due to the spark plugs being in...? i just couldnt in any way...and i didnt want to cause any damage...
So i will have to wait until tomorrow get a 16mm socket so as to remove the spark plugs...My whole tools's collection is missing this specific one, how can this be...shit...

So I'll call it a failure today's effort...

[Sales@RAI]

you mean the 19mm tool? Did you have the car in gear?

Also, are you referring to the cam arrows for timing? You shouldn't have removed the cams

[Doctor]

you mean the 19mm tool? Did you have the car in gear?

Also, are you referring to the cam arrows for timing? You shouldn't have removed the cams

No, I am referring to the 16mm tool as said in the DIY, here

http://www.audiworld.com/tech/pics/eng93_IMG_0379.JPG

So as to reach the TDC where the arrows meet the marks...

BUT, unlike the thread mentions mine doesnt move at all at clockwise rotation. Not at all...
I then tried the crankshaft which has a 19mm bolt of somekind but not a regular one...Nothing there too....

Just removed the spark plugs now, just in case, still nothing...

No gear in the car. I havent removed the cams. Just trying to find the TDC so as to put the 3388 tool and loosen the chain, nothing more than the DIY says...

Any help guys...?

[Doctor]

As shown in the picture, i tried to rotate the purple arrow clockwise, but couldnt in any way,

and then tried to go for the green arrow, which is weirdo 19mm nut but 12 point i think, it moved a bit by hand but then no more...

again, no gear in the car nothing.

what should i do...? Go and buy tomorrow a 19mm nut the one it needs, or something else...?
And will i have to insist if i find resistance...?
Because at the 16mm bolt (purple arrow) i find so much resistance i am afraid to push it even more....

[Dos::Avants]

Remove your spark plugs and put a towel over the ports so nothing falls in. The absence of spark plugs will allow you to turn the crank (green arrow) easily as there won't be any pressure buildup trying to contend with you. Don't turn the purple arrow (cams).

[Doctor]

Remove your spark plugs and put a towel over the ports so nothing falls in. The absence of spark plugs will allow you to turn the crank (green arrow) easily as there won't be any pressure buildup trying to contend with you. Don't turn the purple arrow (cams).

I did remove the plugs. the crank still wont turn by hand. I cant put a tool in this 19mm bolt.

Any suggestion...?