Timing Chain: Service and Repair

Primary Chain, Installing

Special tools, testers and auxiliary items required

• Camshaft Bar (T10068 A)

• Counter-Holder Tool (T10069)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Adjustment Tool (T10332) (Without a mechanical vacuum pump)

• Adjustment Tool (T10363) (With a mechanical vacuum pump)

• Sealant (D 176 501 A1)

Requirements

• Transmission removed

• Drive plate removed

• Oil pan removed

• Sealing flange removed

• Cylinder head cover removed

Procedure

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• Make sure the wires have enough clearance to all moving or hot components.

• The adjustments required depend on how far the engine has been stripped down. The oil pan may be installed only after the sealing flange has been installed.

Install the Primary Chain and Chain Tensioner with Tensioning Rail

- Set the crankshaft to Top Dead Center (TDC) for cylinder 1. The milled tooth on the crankshaft sprocket - arrow - must align with the bearing cap seam.





- Install both locating pins without collars for the guide rail and tighten them to 10 Nm. Install the guide rail on the locating pins.

- Set the oil pump shaft - 1 - with the flat side - arrow - horizontal to the mark - 2 - on the oil pump.





• Note the direction of rotation of the used primary chain. Refer to => [ Marking the Direction
of the Camshaft Timing and Primary Chain ] Service and Repair.

- Install the primary chain into the guide rail and onto the crankshaft sprocket.

- Install the large oil pump sprocket into the chain so that the tab on the sprocket aligns with the mark on the cylinder block - B -.





- Install the large sprocket onto the oil pump shaft.

During installation make sure that the chain runs completely straight in the guide rail from the crankshaft to the oil pump shaft.

• The milled crankshaft sprocket tooth must align with the bearing cap seam - arrow A -.

• The tab on the large oil pump sprocket must align with the mark - arrow B - behind it.

- If the large sprocket cannot be installed, rotate the oil pump slightly.

- Install the chain tensioner with tensioning rail.

- Release the locking splines for the chain tensioner - A - with a small screwdriver and press the tensioning rail against the tensioner.





- Install the chain tensioner in this position and tighten the bolts - arrow - to 8 Nm.





- If the cylinder head has been removed, install it now. Refer to => [ Cylinder Head ] Cylinder Head.

- Install the (T10068 A) into both camshaft grooves.





- Guide the camshaft timing chain through the opening in the cylinder head and cylinder head gasket from above.

- Install the small sprocket with the chain installed, into the recess - arrow - and install the bolt hand tight.





- Secure the vibration damper using (T10069).





- Install a new bolt for the sprockets to the oil pump shaft and tighten it to 60 Nm + 90° (1/4) additional turn. Use strength category 10.9 bolts only.

• Be aware that all sprocket bolts must be replaced.

- Install the guide rail - 2 - through the opening in the cylinder head and secure it with bolts - 1 and 3 -.

- Install the tensioning rail - 4 - and secure it to the cylinder block with the pivot pin - 5 -.





Without a Mechanical Vacuum Pump

- Lubricate the needle bearing on the inside of the drive pinion - 2 - with clean engine oil and insert it with the chain installed into its thrust bearing. Make sure the chain lies taut on the guide rail. Now slide in the bearing shaft - 3 -.





- Make sure that the alignment bushing - 1 - is installed. It is used to secure the (T10332).

- Also secure the position of the drive pinion for the high pressure pump using (T10332).





With a Mechanical Vacuum Pump

- Install the drive gear - 1 - with the chain mounted. Make sure the chain lies taut on the guide rail.





• The notch - arrow - must face upward.

- Lubricate the input shaft - 4 - with clean engine oil and install it.





- Make sure that alignment bushing - 5 - is installed. It is used to secure the (T10363).

- Also secure the position of the drive pinion for the high pressure pump using (T10363). The mark - A - on the high pressure pump sprocket must be at the top.





Continuation for All

- Install the camshaft adjuster, refer to one of the following:

=> [ Vehicles through 11.08 ] Camshaft Adjuster With Timing Chain, Installing.

=> [ Vehicles from 12.08 ] Camshaft Adjuster With Timing Chain, Installing.