Installing Camshaft Actuators

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.

NOTIFICATION 

Dirt and contamination 

• Risk of damage to units or components 
  1. → Protect components from dirt and contamination.
  2. → Clean or replace dirty components.

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 actuators and camshaft stub.
2. Fit the timing chain.
   1. 2.1  Fit the timing chain on the camshaft actuators.
3. Install camshaft actuator (cylinder bank 1).
   1. 3.1  Fit camshaft actuator with timing chain fitted and markings -1 and 2-  aligned with the corresponding 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. Install 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)

      Information 

      Never use sharp-edged tools when working on the central valves.

      Never mask the thread with tape.

5. Replace O-rings -1-  on the central valves -2-  .

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   O-ring on central valve

   1. 5.1  Lever out old O-ring using a plastic wedge and dispose of it.
   2. 5.2  Coat groove on central valve and new O-ring with oil.
   3. 5.3  Carefully slide O-ring over the thread and shoulder -3-  of the central valve and press it on using a plastic wedge.
6. Remove T03006 - locking pin-3-  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 actuator -1-  .
   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 outlet camshaft actuator -1-  to 30 Nm (22 ftlb.)  by turning it anti-clockwise and hold it 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-  .

         Initial tightening 30 Nm (22 ftlb.) 

      2. 7.2.2  Tighten outlet camshaft actuator -1-  .

         Initial tightening 30 Nm (22 ftlb.) 

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         Tightening camshaft actuator

8. Remove locking tools and turn the engine through two turns in direction of rotation of the engine.
9. Check the timing again.

   Setting camshaft timing (V6 Turbo) 

10. If the timing is OK:

    Remove locking tools and tighten camshaft actuators.

    1. 10.1  Fit T90001 - counter-hold tool-3-  and T90002 - counter-hold tool-4-  on the outlet camshaft actuator.
    2. 10.2  Support T90002 - counter-hold tool-4-  on the intake camshaft actuator.

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

    3. 10.3  Tighten outlet camshaft actuator -1-  .

       Final tightening + 35° 

    4. 10.4  Fit T90001 - counter-hold tool-3-  and T90002 - counter-hold tool-4-  on the intake camshaft actuator.
    5. 10.5  Support T90002 - counter-hold tool-4-  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-  .

       Final tightening + 35° 

    7. 10.7  Remove T90001 - counter-hold tool-3-  and T90002 - counter-hold tool-4-  .

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       Final tightening of camshaft actuator

11. Fit screw plug for crankshaft -1-  .

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    Screw plug for crankshaft

    1. 11.1  Replace O-ring on screw plug for crankshaft.
    2. 11.2  Position holder for vacuum reservoir -3-  .
    3. 11.3  Screw in screw plug for crankshaft -1-  in bore -2-  and tighten it.

       > Tightening - torque 40 Nm (29.5 ftlb.) 

12. Loosen engine from assembly support.

    > 100113 - SECURING ENGINE ON ASSEMBLY SUPPORT (V6 TURBO)

13. Install vacuum reservoir -1-  .

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    Vacuum reservoir

    1. 13.1  Position vacuum reservoir -1-  .
    2. 13.2  Screw on and tighten nuts -3-  .

       > Tightening - torque 9 Nm (6.5 ftlb.) 

    3. 13.3  Fit and tighten screws -2-  .

       > Tightening - torque 9 Nm (6.5 ftlb.) 

14. Install left engine carrier -1-  .

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    Left engine carrier

    1. 14.1  Position left engine carrier -1-  .
    2. 14.2  Fit and tighten screws -2-  .

       > Tightening - torque 50 Nm (37 ftlb.) 

15. Install stoppers on camshafts -1-  .

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    Stoppers on camshafts

    1. 15.1  Insert stoppers on camshafts -1-  .
    2. 15.2  Replace screws for stoppers on camshafts -2-  .
    3. 15.3  Screw in and tighten screws for stoppers on camshafts -2-  .

       > Tightening - torque 9 Nm (6.5 ftlb.) 

    4. 15.4  Fit and lock quick connector -3-  for the vacuum line -4-  .