Timing Chain: Service and Repair
WM 153519 Removing and installing timing chains on V6 DFI engines
Tools
Technical values
Preliminary work
1. Remove all engine compartment covers.=> 700219 Removing and installing front trim (engine compartment) - section on "Removing"
2. Remove engine. => 100119 Removing and installing 3.6-litre DFI engine - section on "Removing"
3. Remove transmission.
3.1. For vehicles with manual transmission, see:=> 343519 Removing and installing transmission - section on "Removing"
3.1.1. Remove flywheel.=> 136019 Removing and installing flywheel (DMF) on DFI engines - section on "Removing"
3.2. For vehicles with automatic transmission, see:=> 373519 Removing and installing transmission - section on "Removing"
3.2.1. Remove drive plate for torque converter.=> 136319 Removing and installing drive plate for torque converter on DFI engines - section on "Removing"
4. Remove intake-air distributor. => 244619 Removing and installing intake-air distributor - section on "Removing"
5. Remove cylinder head cover.=> 158219 Removing and installing cylinder head cover - section on "Removing"
6. Remove the timing-case cover at the top and bottom.=> 153319 Removing and installing timing-case cover on V6 DFI engines - section on "Removing"
7. Set crankshaft to compression TDC for cylinder 1 => TDC for cylinder 1.=> 150502 Checking timing on V6 DFI engines - section on "Checking"
TDC for cylinder 1
Information
Component overview
Component overview for timing chains
Removing timing chains
CAUTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled).
-> Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing chain jumps over).
-> Proceed carefully while working as otherwise the engine can be damaged.
-> Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
-> After working on the camshaft wheels, the timing must be set.
-> Please observe general warning notes and working regulations.
Component overview for timing chains
1. Relieve the timing chain.
1.1. Unscrew the chain tensioner -9-.=> 153619 Removing and installing chain tensioner on V6 DFI engines - section on "Removing".
1.2. Unscrew the bearing pin -11-.
1.3. Pull the tensioning rail -8- for the chain tensioner down and out.
1.4. Remove guide rail -23- by unscrewing the fastening screws -20 and 21-.
1.5. Remove timing chain from the camshaft controllers -4 and 25-.
2. Remove camshaft controllers.
Camshaft hexagon
Information
Fix camshaft in place
- To loosen the fastening screws on the camshaft controller, counter the relevant camshaft with an open-ended wrench (a/f 27).
- To prevent damage, remove the camshaft guide.
2.1. Remove outlet camshaft controller -4- by unscrewing the fastening screw -22- (). Counter the camshaft at the hexagon => Camshaft hexagon with an open-ended wrench when doing this.
Information
Fix camshaft in place
- To loosen the fastening screws on the camshaft controller, counter the relevant camshaft with an open-ended wrench (a/f 27).
- To prevent damage, remove the camshaft guide.
2.2. Remove intake camshaft controller -25- by unscrewing the fastening screw -22- (). Counter the camshaft at the hexagon with an open-ended wrench when doing this.
Information
- Always check all components, such as timing chains, sprockets, locking pins and chamfers for wear or damage. Always replace faulty components.
- Always replace all fastening screws for the sprockets.
- Before removing the timing chains, mark the running direction with a coloured pen.
- Maintain the same timing chain running direction during re-installation.
- Never use a prick punch or file for marking.
3. Remove timing chain -3-.
3.1. Remove oil pump sprocket -13- by unscrewing the fastening screw -14-.
Block the crankshaft using special tool brace T10069 ( => Brace T10069 ).
Brace T10069
4. Relieve the drive chain -17-.
4.1. Remove chain tensioner and tensioning rail -15-. To do this, unscrew both fastening screws -2-.
5. Remove the drive chain -17-.
5.1. Remove the sprocket -12- from the oil pump shaft.
Installing timing chains
Component overview for timing chains
1. Install drive chain.
1.1. Check crankshaft position (compression TDC for cylinder 1). => 150502 Checking the timing on V6 DFI engines
NOTICE
Timing chain running direction not maintained
- Risk of damage to sprockets
-> Mark running direction of timing chains.
1.2. Place the drive chain -17- on the crankshaft drive gear wheel -16-.
1.3. Position the oil pump shaft -1- with the flat side up so that it is horizontal to the marking -2-.
Oil pump
1.4. The markings on the sprocket -12- and oil pump -2- must be perfectly aligned. If they are not perfectly aligned, it will not be possible to set the timing correctly.=> 150516 Setting the timing on V6 DFI engines
1.5. Place the drive chain -17- over the sprocket -12- for the oil pump.
Then place the sprocket on the oil pump shaft while ensuring that the drive chain is correctly tensioned in the guide rail -18-.
1.6. Release the chain tensioner -15- using a small screwdriver, then press it together and install it.
The fastening screws -2- must always be replaced so that the chain tensioner is fixed in place with new fastening screws.
Then tighten the fastening screws with a torque wrench.=> Tightening torque: 8 Nm (6 ftlb.)
2. Install timing chain.
2.1. Check the position of the camshafts.
The camshaft guide T10068A must fit into the grooves on the intake and outlet camshafts => Camshaft guide at the same time.
Cylinder 1 must be set to compression TDC. => 150502 Checking the timing on V6 DFI engines
Camshaft guide
2.2. Fix the drive gear wheel for the high-pressure pump in place using adjusting tool T10363. Make sure that the marking -1- on the drive cam for the high-pressure pump is pointing straight up.
Securing drive gear wheel for DFI high-pressure pump
2.3. Guide the timing chain through the timing case from above.
Timing chain
Information
Tips for fitting the camshaft controllers:
- The two camshaft controllers (identified by "24E" on the intake side and "32A" on the outlet side) can be screwed onto the camshaft mounting in one position only because of a dowel pin.
- Turn the sensor wheel 1 on the removed intake camshaft controller as far as it will go to the right. Hold the controller at this position. It must be possible to fit the controller easily on the intake camshaft with the camshaft roller chain set "tightly" and then tighten it hand-tight.
- The outlet camshaft controller is locked in >>idle state<<. As a result, the sensor wheel will not turn when you set the timing. If the locking mechanism is not engaged (locked) in "idle state", the controller must be turned in both directions by hand until it locks. If this is not possible, replace the camshaft controller.
- There must be exactly 16 rollers between the markings on the camshaft controllers "24E" and "32A" and the markings must be flush with the FSI marking. => 150502 Checking the timing on V6 DFI engines
2.4. Turn the sensor wheel -1- on the intake camshaft controller -25- as far as it will go to the right.
Position the intake camshaft controller on the camshaft and fix in place with the fastening screw. The fastening screw must always be replaced.
Sensor wheel on intake camshaft controller
Then place the timing chain over the sprocket on the intake camshaft controller.
Make sure that the timing chain is tensioned correctly between the intake camshaft controller -25- and the drive gear wheel for the high-pressure pump -24-.
2.4.1. Counter the camshaft at the hexagon with an open-ended wrench => Camshaft hexagon.
Tighten the fastening screw -22- using a torque wrench=> Tightening torque: 60 Nm (44 ftlb.) and then tighten further with => Torque angle: 90°.
Camshaft hexagon
2.5. Place the timing chain over the sprocket on the outlet camshaft controller -4-. Fix the outlet camshaft controller in place with the fastening screw -22-. The fastening screw must always be replaced.
2.5.1. Counter the camshaft at the hexagon -arrows- with an open-ended wrench (a/f 27).
Tighten the fastening screw -22- using a torque wrench=> Tightening torque: 60 Nm (44 ftlb.) and then tighten further with => Torque angle: 90°.
3. Tension the timing chain.
3.1. Install tensioning rail -8- for chain tensioner -9-.
3.2. Fix the tensioning rail in place with the bearing pin -11- and then tighten using a torque wrench.=> Tightening torque: 10 Nm (7.5 ftlb.)
3.3. The sealing ring -10- on the chain tensioner -9- must always be replaced.
3.3.1. Then tighten the chain tensioner with a torque wrench.=> Tightening torque: 40 Nm (30 ftlb.).
3.4. Remove the camshaft guide T10068A.
3.5. Remove the adjusting tool T10363 from the drive gear wheel for the high-pressure pump.
4. After you have fitted the timing chain, turn the crankshaft twice and check the timing => 150502 Checking the timing on V6 DFI engines. Reset the timing if necessary => 150516 Setting the timing on V6 DFI engines
Subsequent work
1. Fit the timing-case cover at the top and bottom.=> 153319 Removing and installing timing-case cover on V6 DFI engines - section on "Installing"
2. Install the cylinder head cover.=> 158219 Removing and installing cylinder head cover on V6 DFI engines- section on "Installing"
3. Install intake-air distributor. => 244619 Removing and installing intake-air distributor - section on "Installing"
4. Install transmission.
4.1. For vehicles with manual transmission, see:=> 343519 Removing and installing transmission - section on "Installing"
4.1.1. Install flywheel.=> 136019 Removing and installing flywheel (DMF) on DFI engines - section on "Installing"
4.2. For vehicles with automatic transmission, see:=> 373519 Removing and installing transmission - section on "Installing"
4.2.1. Remove drive plate for torque converter.=> 136319 Removing and installing drive plate for torque converter on DFI engines - section on "Installing"
5. Install engine.=> 100119 Removing and installing 3.6-litre DFI engine - section on "Installing"
6. Install all engine compartment covers. => 700219 Removing and installing front trim (engine compartment) - section on "Installing"