Timing Mechanism Drive Chain and Camshaft Timing Chain
Timing Mechanism Drive Chain and Camshaft Timing Chain
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counter-Holder Tool (T10069)
• Black sealant
• Sealing compound
Removing
• Engine removed. Refer to => [ Engine, Removing ] Engine, Removing.
• Engine and transmission separated. Refer to => [ Engine and DSG Transmission, Separating ] Engine and DSG Transmission, Separating.
• Dual-mass flywheel removed. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.
• Intake manifold removed.
• Cylinder head cover removed. Refer to => [ Cylinder Head Cover ] Service and Repair.
• Coolant thermostat housing removed. Refer to => [ Coolant Thermostat Housing ] Service and Repair.
• Oil pan removed. Refer to => [ Oil Pan ] Oil Pan.
- Set crankshaft to TDC mark by turning crankshaft on vibration damper bolt in direction of engine rotation - arrow -.
- Cams - A - of cylinder 1 must face each other.
- At the same time, (T10068 A) must engage in both shaft grooves. Turn crankshaft 1 additional turn if necessary.
- Identify and disconnect electrical connectors:
1. Camshaft position sensor (G40)
2. Camshaft position (CMP) sensor 2 (G163)
3. Camshaft adjustment valve 1 (N205)
4. Camshaft adjustment valve 1 (exhaust) (N318)
- Remove camshaft timing chain tensioner - arrow -.
- Remove bolts - 1 to 3 - and upper timing chain cover horizontally from cylinder head. When doing so, ensure cylinder head screw is not damaged.
- Remove bolts and remove lower timing chain cover - arrow - horizontally from cylinder block. When doing so, ensure cylinder head bolt is not damaged.
- Press crankshaft seal timing chain side out of cover.
- Identify timing chain direction of rotation with arrow mark before removing, using paint - arrows -.
Risk of damaging timing chain.
• Do not mark chain with punch, notch or something similar.
- Remove bolts - arrows - and remove guide track - 1 -.
- Remove camshaft timing chain from intermediate shaft sprocket.
- Carefully remove camshaft timing chain behind cylinder head seal rib.
- Loosen chain sprocket bolt - arrow - on intermediate shaft approximately 1 turn.
- Counter hold at vibration damper with (T10069) when doing so.
- Remove timing mechanism drive chain tensioner - arrows -.
- Remove bolt - arrow - and remove drive chain together with chain sprockets from intermediate shaft.
Installing
• Tightening specifications, refer to => [ Timing Chain Covers Assembly Overview ] Timing Chain Covers Assembly Overview, => [ Timing Chain Component Overview ] Timing Chain Component Overview.
- When reinstalling a used timing mechanism drive chain, note running direction marking - lower arrow -.
- Install drive chain together with large chain sprocket on intermediate shaft.
• Installation only possible in one position.
- If large chain sprocket cannot be installed, rotate intermediate shaft slightly.
- Check if crankshaft is in "TDC" position:
• Milled drive chain sprocket tooth must align with bearing joint - arrow A -.
• Tab on intermediate shaft sprocket must align with notch - arrow B - on intermediate shaft thrust washer.
- Install small chain sprocket on intermediate shaft.
• Installation only possible in one position.
- Replace the chain sprocket bolt for the intermediate shaft.
- Tighten chain sprocket bolt - arrow - by hand.
- Release locking splines in chain tensioner with small screwdriver - arrow -.
- Press tensioning rail against chain tensioner and tighten chain tensioner in this position - arrows -.
- Tighten chain sprocket bolt - arrow -.
- Counter hold with (T10069) at vibration damper bolt.
- Place the timing chain on the camshaft adjuster in such a way that the 2 individual copper color chain sprockets - CA - align with the markings on the camshaft adjuster. It is possible that the intake camshaft adjust will have to be rotated slightly.
- Mount the timing chain on the small chain sprocket. The marking - B - must align with the center copper color chain link - A -.
- Insert guide track - 1 - and tighten bolts - arrows -.
- Remove (T10068 A).
Risk of timing chain jumping off.
• If the crankshaft is rotated, forcefully press camshaft tensioning rail by hand (instead of with chain tensioner) against camshaft adjuster timing chain - arrow -.
- Set crankshaft to TDC mark by turning crankshaft on vibration damper bolt 2 turns in direction of engine rotation - arrow -.
- Cams - A - of cylinder 1 must face each other.
- At the same time, the (T10068 A) must engage in both shaft grooves.
• Marked links now take on an undefined position.
If the camshaft bar cannot be inserted:
- Repeat valve timing adjustment.
- Clean old sealant from 3 mm holes - arrows - in cylinder head seal.
• With the cylinder head installed only half of the holes in the cylinder head gasket are visible.
- Clean sealing surfaces at engine and both covers; they must be free of oil and grease.
- Check whether lower timing chain cover alignment pins are inserted in cylinder block.
- Lightly coat clean lower timing chain cover sealing surfaces - shown hatched - with sealing paste.
• Lower timing chain cover must be installed within 5 minutes of applying sealing paste.
- Tighten lower timing chain cover bolts - arrow - diagonally in stages.
- Fill 3 mm holes in cylinder head seal - arrows - using black sealant.
- Replace seal in upper timing chain cover. Refer to => [ Upper Timing Chain Cover Seal, Replacing ] Upper Timing Chain Cover Seal, Replacing.
- Check whether alignment sleeves - 2 - and - 3 - are inserted in upper timing chain cover.
- Insert a new gasket - 1 - and a new seal - 4 -.
- Lightly coat clean upper timing chain cover sealing surfaces - shown hatched - with sealing paste.
- Set upper timing chain cover in place and tighten bolts as follows:
1. Tight the bolts - 1 - and - 2 - to 5 Nm.
2. Tighten the bolts - 3 - to 23 Nm.
3. Tight the bolts - 1 - and - 2 - to 10 Nm.
- Tighten camshaft timing chain tensioner - arrow -.
- Turn crankshaft 2 times in direction of engine rotation and check valve timing again.
- Install crankshaft seal, timing chain side. Refer to => [ Crankshaft Seal, Replacing ] Crankshaft Seal, Replacing.
- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Install intake manifold.
- Install coolant thermostat housing. Refer to => [ Coolant Thermostat Housing ] Service and Repair.
- Install oil pan => [ Installing ] Oil Pan.
- Install dual-mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.
- Install engine. Refer to => [ Engine, Installing ] Engine, Installing.
- Add engine oil and check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.