4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting · 2016. 4. 13. ·...

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting http://repair.alldata.com/alldata/article/display.action?componentId=57&iTypeId=376&nonStandardId=4364237&vehicleId=49929&miles=&printFriendly=comple… 1/10 Special tools, equipment, test and inspection devices; required accessories 3268 Camshaft ruler 3406 Counterhold T10029 Spark plug connector tool VAG 1331 torque wrench (5 50 Nm) VAG 1332 torque wrench (40 200 Nm) Procedure With engine removed Install roller chain and chain tensioner with tension bar:

Transcript of 4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting · 2016. 4. 13. ·...

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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Special tools, equipment, test and inspection devices; required accessories ­ 3268 Camshaft ruler ­ 3406 Counter­hold ­ T10029 Spark plug connector tool ­ VAG 1331 torque wrench (5 ­ 50 Nm) ­ VAG 1332 torque wrench (40 ­ 200 Nm)

Procedure With engine removed Install roller chain and chain tensioner with tension bar:

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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­ Set and check position of crankshaft in relation to intermediate shaft. The ground tooth of drive gear ­13­ must be aligned with the bearing parting line (TDC cyl. 1). ­ Install bolt without collar for sliding rail ­2­ and tighten to 10 Nm.

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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­ Install sliding rail ­2­ with roller chain ­1­ and both sprockets ­3­ and ­4­ (note direction of travel of roller chain. The mark on the sprocket for roller chain ­4­ must be aligned with notches ­C­ or ­D­ on the thrust washer. ­ Release stop teeth in chain tensioner with a small screwdriver ­A­. ­ Press tension bar against chain tensioner and tighten chain tensioner to 10 Nm.

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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­ Lock vibration damper in position with locking bracket 3406.

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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­ Tighten sprockets 3 and 4 for intermediate shaft to 100 Nm. ­ Remove locking bracket 3406. ­ Check position of crankshaft in relation to intermediate shaft. The ground tooth of drive gear ­B­ must be aligned with the bearing parting line (TDC cyl. 1). Install camshaft roller chain and chain tensioner with tension bar: ­ Set both camshafts to TDC cyl. 1.

­ Align camshafts with camshaft guide 3268. ­ Install bearing bolt for tension bar and tighten to 18 Nm. ­ Install tension bar for chain tensioner (camshaft roller chain). ­ Install bearing bolt with collar for sliding rail and tighten to 10 Nm.

Note: If the cylinder head is removed:

­ Install cylinder head ­ Push sliding rail onto bearing bolt. Insert short mounting screw with "D6" locking compound and tighten both bolts to 20 Nm. ­ Place camshaft roller chain on intermediate shaft (note direction of travel).

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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­ Mount camshaft sprocket and roller chain on camshaft for cylinder bank 1, 3 and 5 (long camshaft) and counter tighten by hand. ­ Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4, and 6 and tighten by hand.

Note: Coat contact surfaces of the bolt heads with oil when installing.

­ Remove camshaft guide 3268. ­ Tighten mounting bolts for camshaft sprockets to 100 Nm.

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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Note: Hold camshaft ­arrow­ only with open­end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets.

­ Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten mounting bolt to 10 Nm. ­ Replace oil seal for sealing flange. ­ Prepare cylinder head gasket for assembly. ­ Coat sealing surface of cover piece with AMV 188 001 02. ­ Coat O­ring for oil passage seal and insert in cover piece. ­ Install cover piece, insert all mounting bolts and turn in opposite direction slightly. ­ Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm. ­ Install chain tensioner for camshaft roller chain and tighten to 40 Nm.

Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip.

­ Rotate crankshaft two turns in direction of rotation of engine and check valve timing.

With engine installed, cylinder head removed

­ Using mounting bolt for vibration damper, align crankshaft with mark for TDC cyl. 1 ­arrow­.

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If cylinder 1 is correctly at TDC position, it will be possible to see a slot ­arrow­ on intermediate shaft sprockets. If the slot is not visible: ­ Turn crankshaft one turn in direction of rotation of engine.

Note: If the crankshaft is turned with the cylinder head removed, a second mechanic must guide the camshaft roller chain by hand to prevent blocking.

­ Set both camshafts to TDC of cyl. 1.

­ Align camshafts with camshaft guide 3268. ­ Prepare cylinder head gasket for assembly. ­ Install cylinder head. ­ Push sliding rail onto bearing bolt. Insert short mounting bolt with "D6" locking compound and tighten both bolts to 20 Nm. ­ Mount camshaft sprocket with camshaft roller chain to camshaft for cylinder bank 1, 3 and 5 (long camshaft) and turn in opposite direction by hand. ­ Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4 and 6 and turn in opposite direction by hand.

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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Note: Coat contact surfaces of the bolt heads with oil when installing.

­ Remove camshaft guide 3268. ­ Tighten mounting bolts for camshaft sprockets to 100 Nm.

Note: Hold camshaft ­arrow­ only with open­end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets.

­ Coat sealing surface of sealing flange with AMV 188 001 02. ­ Coat O­ring for oil passage seal and insert in cover piece. ­ Install cover piece, insert all mounting bolts and turn in opposite direction slightly. ­ Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm. ­ Install chain tensioner for camshaft roller chain and tighten to 40 Nm.

Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip.

­ Rotate crankshaft twice in engine travel direction and check timing.

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4/13/2016 Timing Chain |Service and Repair, Procedures: Valve Timing, Setting

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Marking roller chains ­ Mark roller chains before removal (e.g., put an arrow in direction of travel with paint).

Note: Do not mark the chain with a center punch, chisel, etc.

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