Installing Timing Chain

NOTIFICATION 

Timing not set correctly 

• Risk of engine damage 
• Rough running engine 
• Loss of engine power 
  1. → Do not use force when fitting the staking tool.
  2. → Make sure that the gap is equal on both sides.
  3. → When inserting the staking tools, do not use force to turn the camshafts against any resistance.
  4. → The engine must be exactly at top dead centre.
  5. → 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. Insert timing chain and tension rail -1-  .
   1. 2.1  Position tension rail -1-  .
   2. 2.2  Screw in and tighten bearing pin for tension rail -2-  .

   > Tightening - torque 23 Nm (17 ftlb.) 

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   Tension rail for cylinder bank 1

3. Remove timing chain.
   1. 3.1  Fit timing chain on sprocket of the intermediate shaft and guide it through the chain housing to the camshafts.
   2. 3.2  Insert camshaft actuators with the splines into the timing chain.
4. Install camshaft actuators (cylinder bank 1).
   1. 4.1  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

5. Install camshaft actuators (cylinder bank 2).
   1. 5.1  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)

6. Install control valves.
   1. 6.1  Replace O-ring.
   2. 6.2  Oil control valves at the thread and screw head contact surface.
   3. 6.3  Screw in control valves as far as required by hand so that the actuator camshafts can still turn on the camshaft.
7. Remove T03006 - locking pin-3-  from the chain tensioner -1-  .

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   Securing chain tensioner

   Information 

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

8. Tighten camshaft actuators -1 and 2-  .
   1. 8.1  A second mechanic must use V.A.G 1331A - torque wrench 6-50 Nm (4.5-37 ftlb.)-5-  with VAS 261 001 - ring spanner insert, SW41 -4-  and T90001 - counter-hold tool-3-  to pre-tension the camshaft actuators to 30 Nm (22 ftlb.)  by turning them anti-clockwise and holding securely.
   2. 8.2  Tighten camshaft actuators -1 and 2-  in the following sequence. (Camshaft actuator is still pre-tensioned) 
      1. 8.2.1  Tighten intake camshaft actuator -2-  .

         Initial tightening 30 Nm (22 ftlb.) 

      2. 8.2.2  Tighten exhaust camshaft actuator

         Initial tightening 30 Nm (22 ftlb.) 

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      Tightening of camshaft actuator

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

    > 150506 - CHECKING AND SETTING TIMING OF CAMSHAFT (V6 TURBO) 

11. If the timing is OK:

    Tighten camshaft actuators -1 and 2-  .

    1. 11.1  Fit T90001 - counter-hold tool-3-  and counter-hold tool T90002 -4-  on the exhaust camshaft actuator -1-  .
    2. 11.2  Support T90002 - counter-hold tool-4-  on the intake camshaft actuator -2-  .

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

    3. 11.3  Tighten exhaust camshaft actuator -1-  .

       Final tightening + 35° 

    4. 11.4  Fit T90001 - counter-hold tool-3-  and T90002 - counter-hold tool-4-  on the intake camshaft actuator -2-  .
    5. 11.5  Support T90002 - counter-hold tool-4-  on the exhaust camshaft actuator -1-  .

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

    6. 11.6  Tighten intake camshaft actuator -2-  .

       Final tightening + 35° 

    7. 11.7  Remove T90001 - counter-hold tool-3-  and T90002 - counter-hold tool-4-  .

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    Final tightening of camshaft actuator

12. Replace O-ring and screw in and tighten screw plug -1-  .

    > Tightening - torque 40 Nm (29.5 ftlb.) 

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    Securing crankshaft

13. Install stoppers on camshafts -1-  .
    1. 13.1  Remove stopper -1-  .
    2. 13.2  Replace screws for stoppers on camshafts -2-  .
    3. 13.3  Screw in and tighten camshaft controller actuators -2-  .

    > Tightening - torque 9 Nm (6.5 ftlb.) 

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    Stoppers on camshafts