Installing Timing Chain

NOTIFICATION 

Timing not set correctly 

• Risk of engine damage 
• Rough running engine 
• Loss of engine power 

  → Do not use force when fitting the staking tool.

  → Make sure that the gap is equal on both sides.

  → When inserting the staking tools, do not use force to turn the camshafts against any resistance.

  → The engine must be exactly at top dead centre.

  → The opposite cylinder must be at ignition TDC.

Information 

The camshaft clamp must be easy to insert and must not be fitted using a striking tool. 

Information 

Camshaft actuator must not be disassembled! 

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Friction plate in camshaft actuator

• The camshaft actuator must never be disassembled. 
• To replace the friction plate -1-  , lever it out carefully using a small slotted screwdriver -2-  .

1. Fit new friction plates between the camshaft actuator and camshaft stub.
2. Install the timing chain.
   1. 2.1  Fit timing chain on sprocket of the intermediate shaft and guide it through the chain housing to the camshafts.
   2. 2.2  Insert camshaft actuators with the splines into the timing chain.
3. Fit camshaft actuators (cylinder bank 1).
   1. 3.1  Fit camshaft actuators with timing chain fitted and the relevant markings (-1 and 2-  ) aligned with the markings on the camshaft housing -Arrows-  on the camshafts.

      Check that the friction plates are fitted and seated correctly.

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      Markings on camshaft actuator (cylinder bank 1)

4. Fit camshaft actuator (cylinder bank 2).
   1. 4.1  Fit camshaft actuator with timing chain fitted and markings -1 and 2-  aligned with the corresponding markings on the camshaft housing -Lines-  on the camshafts.

      Check that the friction plates are fitted and seated correctly.

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      Markings on camshaft actuator (cylinder bank 2)

5. Fit control valves.
   1. 5.1  Replace O-ring.
   2. 5.2  Oil control valves at the thread and screw head contact surface.
   3. 5.3  Screw in control valves as far as required by hand so that the actuator camshafts can still turn on the camshaft.
6. > T03006 - Locking pin  (-3-  ) can now be removed from the chain tensioner (-1-  ).

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   Fixing device for chain tensioner

   Information 

   You will need a second mechanic to help you with this step.

7. Tighten camshaft actuators (-1 and 2-  ).
   1. 7.1  A second mechanic must use > V.A.G 1331A - torque wrench 6-50 Nm (4.5-37 ftlb.)  (-5-  ) with > VAS 261 001 - ring tool attachment, a/f 41  (-4-  ) and > T90001 - counterhold tool  (-3-  ) to pre-tension the camshaft actuators to 30 Nm (22 ftlb.)  by turning them anti-clockwise and holding securely.
   2. 7.2  Tighten camshaft actuators (-1 and 2-  ) in the following sequence. (Camshaft actuator is still pre-tensioned) 
      1. 7.2.1 Tighten intake camshaft actuator (-2-  ) to > Initial tightening 30 Nm (22 ftlb.)  .
      2. 7.2.2 Tighten outlet camshaft actuator (-1-  ) to > Initial tightening 30 Nm (22 ftlb.)  .

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         Tightening camshaft actuator

8. Remove staking tools and turn the engine clockwise through two turns.
9. Check the timing again.

   > Refer to the appropriate service information.

10. If the timing is OK:

    Tighten camshaft actuators (-1 and 2-  ).

    1. 10.1  > T90001 - Counterhold tool  (-3-  ) and counterhold tool T90002  (-4-  ) must be fitted on the outlet camshaft actuator (-1-  ).
    2. 10.2  > T90002 - Counterhold tool  (-4-  ) must be supported on the intake camshaft actuator (-2-  ).

       Turn the crankshaft slightly to do this if necessary. (Only turn clockwise) 

    3. 10.3  Tighten outlet camshaft actuator (-1-  ) to > Final tightening + 35°  .
    4. 10.4  > T90001 - Counterhold tool  (-3-  ) and > T90002 - counterhold tool  (-4-  ) must be fitted on the intake camshaft actuator (-2-  ).
    5. 10.5  > T90002 - Counterhold tool  (-4-  ) must be supported on the outlet camshaft actuator (-1-  ).

       Turn the crankshaft slightly to do this if necessary. (Only turn clockwise) 

    6. 10.6  Tighten intake camshaft actuator (-2-  ) to > Final tightening + 35°  .
    7. 10.7  > T90001 - Counterhold tool  (-3-  ) and > T90002 - counterhold tool  (-4-  ) must now be removed.

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       Final tightening of camshaft actuator