Camshaft Timing Chain, Removing From Camshafts: Installing

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NOTE:

Replace any bolts that were tightened with an additional turn.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

The timing mechanism drive chain is installed, refer to INSTALLING .
Crankshaft locked in "TDC" position with camshaft locating tool T40264/3

Fig 1: Identifying Camshaft Locating Tool T40264/3
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Camshaft locating tool T40264/2 tightened on the left cylinder head to 12 Nm -arrows-.

Fig 2: Locating Right Bolt -Right Arrow- On Camshaft Locating Tool T40264/2
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Camshaft locating tool T40264/1 tightened on the right cylinder head to 12 Nm -arrows-.

Fig 3: Locating Right Bolt -Right Arrow- On Camshaft Locating Tool T40264/1
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Cylinder Bank 1 (Right):

Fig 4: Aligning Grooves

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CAUTION:

The engine could be damaged.

The camshaft adjuster must only be installed according to the following work steps.

Install the camshaft adjuster according to the marks applied during removal.
the groove -1- and/or -4- in the camshaft adjuster must align with the adjustment window -2- and/or -3-.

-- Install the camshaft adjuster according to the marks applied during removal.

Fig 5: Locating Camshaft Adjuster Bolts

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-- Position the camshaft timing chain on the drive sprocket and the camshaft adjuster and loosely install bolts -1, 2-.

Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

-- Remove the Locking Pin T40071.

Cylinder Bank 2 (Left):

Fig 6: Aligning Grooves

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CAUTION:

The engine could be damaged.

The camshaft adjuster must only be installed according to the following work steps.

Install the camshaft adjuster according to the marks applied during removal.
the groove -1- and/or -4- in the camshaft adjuster must align with the adjustment window -2- and/or -3-.

-- Install the camshaft adjuster according to the marks applied during removal.

Fig 7: Removing Bolts By Counterholding With Wrench And Wrench - Camshaft T40269

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-- Position the camshaft timing chain on the drive sprocket and the camshaft adjuster and loosely install bolts -1, 2-.

Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

-- Remove the Locking Pin T40071.

Cylinder Bank 1 (Right):

-- Position the Wrench - Camshaft T40269 on the camshaft adjuster for the intake camshaft.

-- Position the Torque Wrench 1332 40-200 Nm VAG 1332 with the Torque Wrench 1332 Insert - Open Ring Wrench - 24 mm VAG 1332/9 on the Wrench - Camshaft T40269.

-- Have a second technician pre-tension the camshaft adjuster in direction of -arrow- to 40 Nm.

Fig 8: Adjusting Intake Camshaft

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-- Tighten the bolts as follows while the camshaft adjuster is still held under tension.

Step	Bolt	Tightening specification
1.	-1-	to the camshaft to 60 Nm
1.	-2-	to the camshaft to 60 Nm

-- Remove the Wrench - Camshaft T40269.

-- Remove the camshaft locating tool T40264/1 -arrows-.

Fig 9: Locating Right Bolt -Right Arrow- On Camshaft Locating Tool T40264/1

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Cylinder Bank 2 (Left):

Fig 10: Adjusting Exhaust Camshaft

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-- Position the Wrench - Camshaft T40269 on the camshaft adjuster for the exhaust camshaft.

-- Position the Torque Wrench 1332 40-200 Nm VAG 1332 with the Torque Wrench 1332 Insert - Open Ring Wrench - 24 mm VAG 1332/9 on the Wrench - Camshaft T40269.

-- Have a second technician pre-tension the camshaft adjuster in direction of -arrow- to 40 Nm.

-- Tighten the bolts as follows while the camshaft adjuster is still held under tension.

Step	Bolt	Tightening specification
1.	-1-	to the camshaft to 60 Nm
1.	-2-	to the camshaft to 60 Nm

-- Remove the Wrench - Camshaft T40269.

-- Remove the camshaft locating tool T40264/2 -arrows-.

Fig 11: Locating Right Bolt -Right Arrow- On Camshaft Locating Tool T40264/2

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Cylinder Bank 1 (Right):

Fig 12: Locating Camshaft Adjuster Bolts

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-- Tighten the camshaft adjuster bolts on the right cylinder head as follows:

Step	Bolt	Tightening specification
2.	-1-	final tightening specification at the camshaft, refer to OVERVIEW - CAMSHAFT TIMING CHAIN .
2.	-2-	final tightening specification at the camshaft, refer to OVERVIEW - CAMSHAFT TIMING CHAIN .

Cylinder Bank 2 (Left):

Fig 13: Removing Bolts By Counterholding With Wrench And Wrench - Camshaft T40269

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-- Tighten the camshaft adjuster bolts on the left cylinder head as follows:

Step	Bolt	Tightening specification
2.	-1-	final tightening specification at the camshaft, refer to OVERVIEW - CAMSHAFT TIMING CHAIN .
2.	-2-	final tightening specification at the camshaft, refer to OVERVIEW - CAMSHAFT TIMING CHAIN .

Continuation For Both Cylinder Banks:

Fig 14: Identifying Camshaft Locating Tool T40264/3

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-- Remove the camshaft locating tool T40264/3.

-- Turn the crankshaft two turns in the direction of engine rotation in direction of -arrow- using the Wrench - 21 mm T40263 and Crankshaft Turning Tool T40272 until the crankshaft is once again at "TDC".

Fig 15: Identifying Crankshaft Turning Tool T40272

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NOTE: If it is accidentally rotated beyond "TDC", rotate it back approximately 30 degrees and set it to "TDC" again.

The threaded holes -arrows- in the camshafts must face upward.

Fig 16: Identifying Sealing Plug
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NOTE: The right camshaft housing is shown in the illustration.

Cylinder Bank 1 (Right):

Fig 17: Locating Right Bolt -Right Arrow- On Camshaft Locating Tool T40264/1

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-- Insert the camshaft locating tool T40264/1 into the right cylinder head and tighten -arrows-.

Tightening specification 12 Nm.

Cylinder Bank 2 (Left):

Fig 18: Locating Right Bolt -Right Arrow- On Camshaft Locating Tool T40264/2

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-- Insert the camshaft locating tool T40264/2 into the left cylinder head and tighten -arrows-.

Tightening specification 12 Nm.

Continuation for Both Cylinder Banks:

Fig 19: Identifying Camshaft Locating Tool T40264/3

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-- Install the camshaft locating tool T40264/3 at the vibration damper opening all the way by hand into the cylinder block.

The camshaft locating tool T40264/3 must engage into the hole in the cylinder; if not, repeat the adjustment.

-- Remove the camshaft locating tools T40264/1 and T40264/2.

-- Remove the camshaft locating tool T40264/3.

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the ignition coil for cylinder "7", refer to IGNITION COILS WITH POWER OUTPUT STAGES, REMOVING AND INSTALLING, CYLINDER BANK 2 (LEFT) .

-- Install the high pressure line, refer to HIGH PRESSURE PIPE, INSTALLING .

-- Install the wires, refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and => Wiring Diagram.

-- Install the vacuum actuator for the turbocharger, refer to OVERVIEW - TURBOCHARGER .

-- Install the timing chain cover, refer to TIMING CHAIN COVER, REMOVING AND INSTALLING .