Cylinder Block Assembly: Description and Operation
Engine Overview
Part I, => [ Timing Chains and Adjusters ]
Part II, => [ Cylinder Block, Vibration Damper and Lubrication Components ]
• The engine is to be secured to the engine and transmission holder (VAS 6095) when performing assembly work.
• If large quantities of metal particles or abraded material are detected during engine repairs, it may be an indication of a damaged crankshaft or rod bearings. To prevent further damage, perform the following steps after the repair:
• Carefully clean the oil passages.
• Replace the oil check valve (if installed).
• Replace the oil injection jets.
• Replace the oil cooler.
• Replace the oil filter.
Timing Chains and Adjusters
1 Control Housing
• Lubricate the contact surface of the seals before installing.
• Removing and installing, refer to => [ Camshafts ] Service and Repair.
• Overview, refer to => [ Control Housing Overview ] Description and Operation.
• Check the control housing strainer for contamination before installation. Refer to=> [ Control Housing Overview ] Description and Operation.
2 Bolt
• 8 Nm
• Install the control housing bolts using locking compound (D 000 600 A2).
3 Timing Chain
• For the camshafts.
• Mark the direction of rotation before removing (installed position).
• Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
4 Exhaust Camshaft Adjuster
• Identification: 32A
• Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
5 Seal
• Replace
6 Oil Pump
• Removing and installing, refer to => [ Oil Pump ] Oil Pump.
7 Bolt
• 8 Nm
• Install using locking compound (D 000 600 A2).
8 Tensioning Rail
• For the timing chain - item 3 -.
9 Chain Tensioner
• 50 Nm
• For the timing chain - item 3 -.
• Only rotate the engine with the chain tensioner installed.
10 Seal
• Replace if damaged or leaking.
11 Pivot Pin
• 10 Nm
• For the tensioning rail - item 8 -.
12 Sprocket
• For the timing chain - item 17 -.
• Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
13 Sprocket
• For the timing chain - item 3 -.
• Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing
14 Bolt
• 60 Nm + 90° (1/4) additional turn.
• Replace
• Only use bolts with a strength category of 10.9.
15 Chain Tensioner with Tensioning Rail
• For the timing chain - item 17 -.
• Before installation, release the locking device in the chain tensioner using a small screwdriver and press the tensioning plate against the chain tensioner.
• Only rotate the engine with the chain tensioner installed.
16 Drive Sprocket
• Integral part of the crankshaft.
• Milled tooth aligned with crankshaft main bearing cap joint = cylinder 1 Top Dead Center (TDC). Refer to => [ Oil Pump Drive Timing Chain, Installing ] Oil Pump Drive Timing Chain, Installing.
17 Timing Chain
• For the oil pump drive.
• Mark the direction of rotation before removing (installed position).
• Install, refer to => [ Oil Pump Drive Timing Chain, Installing ] Oil Pump Drive Timing Chain, Installing.
18 Guide Rail
• For the timing chain - item 17 -.
• Together with the timing chain, installing. Refer to => [ Oil Pump Drive Timing Chain, Installing ] Oil Pump Drive Timing Chain, Installing.
19 Locating Pin without Collar
• 10 Nm
• For the guide rail - item 18 -.
20 Pivot Pin
• 10 Nm
21 Bolt
• 23 Nm
22 Bolt
• 60 Nm + 90° (1/4) additional turn.
• Replace
• The contact surfaces of the adjuster wheel and bolt head must be dry when installing.
• When removing and installing, counter hold the camshaft using a 27 mm open end wrench. Refer to => [ Camshafts ] Service and Repair.
23 Guide Rail
• For the timing chain - item 3 -.
24 High Pressure Pump Drive Pinion
• With the needle bearing lying inside.
• Lubricate the needle bearing before installing.
25 Intake Camshaft Adjuster
• Identification: 24E
• Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
26 Camshaft Adjustment Valve 1 (Exhaust) (N318)
• For the exhaust camshaft.
• Mark the connector belonging to the component before disconnecting.
27 Camshaft Adjustment Valve 1 (N205)
28 Guide Rail
• For the timing chain - item 3 -
• Clipped into the control housing.
Identifying the Timing Chain
- Mark the timing chains before removing (for example, using paint, arrow pointing in the direction of rotation).
• DO NOT mark the chain using a center punch or similar means!
Cylinder Block, Vibration Damper and Lubrication Components
Engine mount and bracket, removing and installing. Refer to => [ Engine Mount and Bracket ] Service and Repair.
1 Oil Dipstick
• Oil level must not be above the Max. mark!
2 Oil Dipstick Guide Tube
• Secured to the intake manifold by a bolt.
3 Bolt
• 6 Nm
• To the intake manifold, for the guide tube.
4 Cylinder Block
• Sealing flange and drive plate overview. Refer to => [ Sealing Flanges and Drive Plate Overview ] Description and Operation.
• Crankshaft overview. Refer to => [ Crankshaft Overview ] Description and Operation.
• Piston and connecting rod overview. Refer to => [ Pistons and Connecting Rod Overview ] Description and Operation.
5 Oil Check Valve
• Only installed on vehicles through 11.06.
• Note the installed position.
• Clean if badly contaminated.
• See note in => [ Engine Overview ] Description and Operation.
• Removing and installing, refer to => [ Oil Check Valve, Removing and Installing ] Oil Pan, Pump and Filter Housing Overview.
6 Knock Sensor (KS) 1 (G61)
• Installed location: between cylinders 1 and 3.
7 Bolt
• 20 Nm
• Tightening specification affects the function of the KS.
8 Bolt
• 8 Nm
• Replace
9 Sprocket
• For the oil pump.
• Camshaft adjustor with timing chain, installing. Refer to => [ Camshaft Adjuster with Timing Chain, Installing ] Camshaft Adjuster with Timing Chain, Installing.
10 Bolt
• 60 Nm + 90° (1/4) additional turn.
• Replace
• Only use bolts with a strength category of 10.9.
11 Oil Pump
• Removing and installing, refer to => [ Oil Pump ] Oil Pump.
12 Seal
• Replace
• Lubricate before installing.
13 O-ring
• Replace
14 Gasket
• Replace
15 Flange
• Note the installed position.
16 Oil Pressure Line
17 Oil Drain Plug
• 30 Nm
• Replace
• With a permanent seal
18 Oil Pan
• Removing and installing, refer to => [ Oil Pan ] Service and Repair.
19 Bolt
• 10 Nm
20 Oil Level Thermal Sensor (G266)
21 Bolt
• 12 Nm
22 Oil Intake Pipe
• For the oil pump.
23 Engine Speed (RPM) Sensor (G28)
24 Bolt
• 10 Nm
25 Oil Filter Housing/Left Engine Mount Bracket
• Overview, refer to => [ Oil Filter Housing Overview ] Description and Operation.
• Coolant hose connection diagram. Refer to => [ Coolant Hose Connection Diagram ] [1][2]Cooling System.
• Engine mount and bracket, removing and installing. Refer to => [ Engine Mount and Bracket ] Service and Repair.
26 Bolt
• 23 Nm
27 Bolt
• 25 Nm
28 Knock Sensor (KS) 2 (G66)
• Installed location: between cylinders 4 and 6.
29 Bolt
• 25 Nm
• Used for alignment.
30 Accessory Bracket
• For the generator, Air/Conditioning (A/C) Compressor, and power steering pump.
31 Vibration Damper
• Removing and installing the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
32 Bolt
• 100 Nm + 180° (1/2) additional turn
• Loosening and tightening.
Loosening and Tightening the Vibration Damper Bolt
CAUTION!
Check the rubber isolator between the inner and outer rings of the vibration damper for cracks and flaking. If rubber isolator damage is identified, the vibration damper must be replaced.
- Lock the vibration damper using the (T10069) when loosening or tightening the bolt.
- Clean the threads in the crankshaft using a M18 x 1.5 tap.
- Replace the vibration damper bolt.
- Tighten the bolt using the (V.A.G 1601).
Tightening specification: 100 Nm + 180° (1/2) additional turn.
• The additional turning may be performed in several stages.