Valve Timing, Adjusting (Installation)
Valve timing, adjusting
(Installing timing chains)
Special Tools, Testers And Auxiliary Items
- 3406 Counter-hold tool
- 3268 Camshaft setting bar
- VAG 1331 Torque wrench (5 to 50 Nm)
- VAG 1332 Torque wrench (40 to 200 Nm)
With Engine Removed
- Install single chain and chain tensioner with tensioning plate
- Set/check position of crankshaft to intermediate shaft
Ground down tooth on crankshaft sprocket -B- must align with the main bearing joint = TDC for cyl. 1)
- Install pin (without collar) for guide rail -2- and tighten
25 Nm (18 ft lb)
- Install guide rail -2- with single chain -1- and both sprockets -3- and -4-
- Note direction of rotation for single chain made during removal
Mark on single chain sprocket -4- must align with notch -C- or -D- on the thrust washer
- Release locking spline in chain tensioner using a small screwdriver -A-
- Press chain tensioner against tensioner plate, then tighten chain tensioner
10 Nm (7 ft lb)
- Lock vibration damper using 3406 counter-hold tool
- Tighten intermediate shaft sprockets -3- and -4-
100 Nm (74 ft lb)
- Check position of crankshaft relative to intermediate shaft
Ground down tooth on crankshaft sprocket -13- must align with the main bearing joint (= TDC for cyl. 1)
- Install double chain and chain tensioner with tensioning plate
- Position camshafts using camshaft ruler -3268-
- Install tensioning plate pivot pins and tighten
25 Nm (18 ft lb)
- Install tensioning plate for chain tensioner (upper chain)
- Install locating pin with collar for guide rail and tighten
25 Nm (18 ft lb)
With Cylinder Head Removed
- Place guide rail on locating pin, insert short mounting bolt using "D6" locking fluid and tighten both bolts
20 Nm (15 ft lb)
- Place upper chain on intermediate shaft
Note direction of engine rotation for double chain
- Install camshaft sprocket and upper chain to camshaft for cylinders 2, 4 and 6 (short camshaft) and hand tighten
- Install camshaft sprocket (with sensor wheel for Camshaft Position sensor) and upper chain on camshaft for cylinders 1, 3 and 5 and tighten by hand
NOTE:
Contact surfaces of timing chain and sensor wheel must be dry when installing
Oil bolt head contact surfaces when installing
- Remove camshaft bar -3268-
- Tighten camshaft sprocket mounting bolts
100 Nm (74 ft lb)
NOTE: Only counter-hold using a 24 mm open end wrench on the camshaft -arrow-. Camshaft bar -3268- must not be installed when tightening or loosening the sprockets.
- Coat sealing surface of sealing flange with AMV 188 001 02 and install
- Tighten mounting bolt
10 Nm (7 ft lb)
- Replace sealing flange oil seal
- Prepare cylinder head gasket for assembly
- Coat camshaft sprocket cover sealing flange with -AMV 188 001 02-
- Oil O-ring and insert in camshaft sprocket cover
- Install cylinder head cover, insert bolts and lightly tighten
- Tighten M8 mounting bolt
25 Nm (18 ft lb)
- Tighten M6 mounting bolts
10 Nm (7 ft lb)
- Install chain tensioner and tighten
30 Nm (22 ft lb)
NOTE:
If the chain tensioner has been pulled apart, bleed before installing.
Beginning with engine number AES-003279 only signle chains for camshaft drive are installed. Therefore, chain tensioner does not have oil bore and is no longer bled.
Only turn engine with chain tensioner installed! Otherwise the lower or upper chain will jump sprockets.
- Turn crankshaft two full turns in direction of engine rotation and check valve timing
Engine Installed, Cylinder Head Removed
- Set crankshaft to TDC (cyl. 1) marks -arrow- by turning crankshaft in direction of engine rotation using vibration damper mounting bolt
If the TDC cyl. 1 setting is correct, it is possible to see a notch on the intermediate shaft sprockets -arrow-
If notch is not visible:
- Turn crankshaft one full turn in direction of engine rotation
NOTE: If crankshaft must be turned with cylinder head removed, use a 2nd technician to hand guide upper chain to prevent it from jamming.
- Position camshafts using 3268 camshaft tool
- Prepare cylinder head gasket for assembly
- Install cylinder head
- Place guide rail on locating pin
- Insert short mounting bolt using D6 locking fluid and tighten
20 Nm (15 ft lb)
- Install camshaft sprocket and upper chain to camshaft for cylinders 2, 4 and 6 (short camshaft), hand-tighten
- Install camshaft sprocket (with trigger wheel for Camshaft Position sensor) and upper chain on camshaft for cylinders 1, 3 and 5, hand-tighten
NOTE:
Contact surfaces of timing chain and sensor wheel must be dry when installing
Oil bolt head contacting surfaces when installing
- Remove camshaft tool -3268-
- Tighten camshaft sprocket mounting bolts
100 Nm (74 ft lb)
NOTE: Only counter-hold using a 24 mm open end wrench on camshaft -arrow-. Camshaft tool -3268- must not be installed when tightening or loosening sprockets.
- Coat sealing flange sealing surface with AMV 188 001 02
- Oil O-ring and insert in camshaft sprocket cover
- Install camshaft cover
- Install all bolts and lightly tighten
- Tighten M8 bolt
25 Nm (18 ft lb)
- Tighten M6 bolt
10 Nm (7 ft lb)
- Install upper chain, chain tensioner and tighten
30 Nm (22 ft lb)
NOTE:
If the chain tensioner has been pulled apart, bleed before installing
Beginning with engine number AES-003279 only signle chains for camshaft drive are installed. Therefore, chain tensioner does not have oil bore and is no longer bled.
CAUTION: Only turn engine with chain tensioner installed! Otherwise the chain (single or double) will jump the track!
- Turn crankshaft two full turns in direction of engine rotation and check valve timing