Checking Timing Of Camshafts

1. Turn the crankshaft clockwise until the marking on the vibration damper -1-  is positioned at TDC -2-  .

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   TDC marking on vibration damper

2. The markings on the camshaft actuators (cylinder bank 1) -1 and 2-  must be aligned with the reference points on the camshaft housing -Arrows-  . Turn the crankshaft one further turn clockwise if necessary.

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   Markings on camshaft actuator (cylinder bank 1)

3. The markings on the camshaft actuators (cylinder bank 2) -1 and 2-  must be aligned with the reference points -Lines-  on the camshaft housing.

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   Markings on camshaft actuator (cylinder bank 2)

4. Remove stoppers on camshafts -1-  .
   1. 4.1 Release and disconnect quick connector. -3- 
   2. 4.2 Move vacuum hoses -4-  aside so that the stoppers on the camshafts -1-  are accessible.
   3. 4.3 Unscrew screws -2-  .
   4. 4.4 Remove stoppers on camshafts -1-  .

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   Stoppers on camshafts

5. Screw adapter T40331/2 -1-  from > T40331 - camshaft clamp  tool set into the camshaft housing on cylinder bank 1 and tighten to 9 Nm (6.5 ftlb). 

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   Adapter on camshaft housing, cylinder bank 1

6. Screw adapter T40331/3 -1-  from > T40331 - camshaft clamp  tool set into the camshaft housing on cylinder bank 2 and tighten to 9 Nm (6.5 ftlb)  .

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   Adapter on camshaft housing, cylinder bank 2

   Information 

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

   Information 

   It may be necessary for a second mechanic to carefully position the camshafts at the actuators using > T90001 - counter-hold tool  and > VAS 261 001 - ring spanner socket, a/f 41  .

7. Fit > T40331 - camshaft clamp  .
   1. 7.1 Insert > T40331 - camshaft clamp  .

      Cylinder bank 1

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      Camshaft clamps on cylinder bank 1

      1	T40331/1 - The letter "A" must be facing you.
      2	T40331/9
      3	T40331/2
      4	T40331/5 - Outlet camshaft
      5	T40331/4 - Intake camshaft

      1. 7.1.1 T40331/9 -2-  must be screwed in by hand. Tighten screws on the camshaft clamp -Arrows-  to 9 Nm (6.5 ftlb).
   2. 7.2 Cylinder bank 2

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      Camshaft clamps on cylinder bank 2

      1	T40331/1 - The letter "B" must be facing you.
      2	T40331/9
      3	T40331/3
      4	T40331/5 - Outlet camshaft
      5	T40331/6 - Intake camshaft

      1. 7.2.1 T40331/9 -2-  must be screwed in by hand. Tighten screws on the camshaft clamp -Arrows-  to 9 Nm (6.5 ftlb.)  .
8. Secure the crankshaft.
   1. 8.1 Unscrew screw plug -1-  from bore -2-  .
   2. 8.2 Screw > T40069 - locking pin  into the bore -2-  by hand.

      Turn the crankshaft back and forth slightly to do this, if necessary.

   3. 8.3 Tighten > T40069 - locking pin  to 20 Nm (15 ftlb.). 

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   Securing crankshaft

   NOTE: 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.

9. If the locking tools can be inserted as described, the timing is OK.

   If the locking tools cannot  be inserted as described, the timing must be set.

Information 

• The pictures shown in this document may differ from the original. 

If the locking tools cannot be inserted as described: 

1. Remove all tools.
2. Fit > VAS 261 001 - ring spanner socket, a/f 41  with > T90001 - counter-hold tool  on the camshaft actuator. The > T90001 - counter-hold tool  can only be inserted at one position. To do this, the markings on the camshaft actuator -1-  and chain housing -2-  must be aligned.

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   Special tool T90001 on camshaft actuator

   Information 

   Never use the camshaft clamps -T40331- as a counterhold tool for loosening the camshaft controllers.

3. Release camshaft actuator -1-  .
   1. 3.1 Hold camshaft actuator -1-  with > VAS 261 001 - ring spanner socket a/f 41-2-  and > T90001 - counterhold tool-3-  and loosen half a turn with > T90000 - socket E24  .

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   Camshaft actuator

4. Screw adapter T40331/2 -1-  from > T40331 - camshaft clamp  tool kit into the camshaft housing on cylinder bank 1 and tighten to 9 Nm (6.5 ftlb.)  .

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   Adapter on camshaft housing, cylinder bank 1

5. Screw adapter T40331/3 -1-  from > T40331 - camshaft clamp  tool kit into the camshaft housing on cylinder bank 2 and tighten to 9 Nm (6.5 ftlb.)  .

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   Adapter on camshaft housing, cylinder bank 2

   Information 

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

   Information 

   It may be necessary for a second mechanic to carefully position the camshafts at the actuators using > T90001 - counter-hold tool  and > VAS 261 001 - ring spanner socket, a/f 41  .

6. Fit > T40331 - camshaft clamp  .
   1. 6.1 Insert > T40331 - camshaft clamp  .

      Cylinder bank 1

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      Camshaft clamps on cylinder bank 1

      1	T40331/1 - The letter "A" must be facing you.
      2	T40331/9
      3	T40331/2
      4	T40331/5 - Exhaust camshaft
      5	T40331/4 - Intake camshaft

      1. 6.1.1 Screw T40331/9 -2-  in by hand. Tighten screws on the camshaft clamps -Arrows-  to 9 Nm (6.5 ftlb.). 
   2. 6.2 Cylinder bank 2

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      Camshaft clamps on cylinder bank 2

      1	T40331/1 - The letter "B" must be facing you.
      2	T40331/9
      3	T40331/3
      4	T40331/5 - Exhaust camshaft
      5	T40331/6 - Intake camshaft

      1. 6.2.1 Screw T40331/9 -2-  in by hand. Tighten screws on the camshaft clamps -Arrows-  to 9 Nm (6.5 ftlb.). 
7. Secure the crankshaft.
   1. 7.1 Screw > T40069 - locking pin-1-  into the bore -2-  by hand.

      Turn the crankshaft back and forth slightly to do this, if necessary.

   2. 7.2 Tighten > T40069 - locking pin-1-  to 20 Nm (15 ftlb.). 

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   Securing crankshaft

   Information 

   The markings on the camshaft actuators must be aligned with the reference points on the camshaft housing.

   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-  .
8. The markings on the camshaft actuator (cylinder bank 1) -1 and 2-  must be aligned with the corresponding markings on the camshaft housing -Arrows-  .

   If the markings on the camshaft actuator -1 and 2-  are not aligned with the corresponding markings on the camshaft housing -Arrows  the camshaft actuators must be removed and positioned correctly.

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   Markings on camshaft actuator (cylinder bank 1)

   Information 

   The markings on the camshaft actuators must be aligned with the reference points on the camshaft housing.

   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-  .
9. The markings on the camshaft actuator (cylinder bank 2) -1 and 2-  must be aligned with the corresponding markings on the camshaft housing -Lines-  .

   If the markings on the camshaft actuator -1 and 2-  are not aligned with the corresponding markings on the camshaft housing -Lines  the camshaft actuators must be removed and positioned correctly.

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   Markings on camshaft actuator (cylinder bank 2)

   Information 

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

10. Tighten camshaft actuator -1 and 2-  .

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    Tightening of camshaft actuator

    1. 10.1 Have a second mechanic use > V.A.G 1331A - torque wrench 6-50 Nm (4.5-37 ftlb.)-5-  with > VAS 261 001 - ring spanner socket a/f 41-4-  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. 10.2 Pre-tighten camshaft actuators to > Initial tightening 30 Nm (22 ftlb.)  in the following sequence. (Camshaft actuator is still pre-tensioned) 
       1. 10.2.1 Intake camshaft actuator for cylinder bank 1.
       2. 10.2.2 Exhaust camshaft actuator for cylinder bank 1.
       3. 10.2.3 Exhaust camshaft actuator for cylinder bank 2.
       4. 10.2.4 Intake camshaft actuator for cylinder bank 2.
    NOTE: 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.

11. Remove staking tools, perform two revolutions of the engine and check the timing again.
    1. 11.1 Secure the crankshaft using locking pin.
    2. 11.2 Have a second mechanic use > V.A.G 1331A - torque wrench 6-50 Nm (4.5-37 ftlb.)  with > VAS 261 001 - ring spanner socket a/f 41  and > T90001 - counter-hold tool  to pre-tension the camshaft actuators to 30 Nm (22 ftlb.)  by turning them anti-clockwise and holding securely.
    3. 11.3 The camshaft fixing pin must insert easily. Do not insert the camshaft fixing pin using a hammer.
    4. 11.4 If the camshaft fixing pin cannot be inserted:
       1. 11.4.1 Remove camshaft fixing pin and locking pin on the crankshaft.
       2. 11.4.2 Plug the camshaft fixing pin as far into the camshafts as it will go. Turn the crankshaft slightly if necessary.
       3. 11.4.3 Loosen actuators by half a turn using the special tools.
       4. 11.4.4 Fix crankshaft in place with the locking pin and repeat the settings.
12. Tighten camshaft actuator -1 and 2-  .
    1. 12.1 Fit > T90001 - counter-hold tool-3-  and > T90002 - counter-hold tool-4-  on the exhaust camshaft actuator -1-  .
    2. 12.2 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. 12.3 Tighten exhaust camshaft actuator -1-  to > Final tightening + 35°  .
    4. 12.4 Fit > T90001 - counter-hold tool-3-  and > T90002 - counter-hold tool-4-  on the intake camshaft actuator -2-  .
    5. 12.5 Support > T90002 - counter-hold tool-4-  on the exhaust camshaft actuator -1-  .
    6. Turn the crankshaft slightly to do this if necessary. (Only turn clockwise) 
    7. 12.6 Tighten intake camshaft actuator -1-  to > Final tightening + 35°  .
    8. 12.7 Remove > T90001 - counter-hold tool-3-  and > T90002 - counter-hold tool-4-  .

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Final tightening of camshaft actuator