Intermediate Shaft and Timing Chains, Installing

Intermediate Shaft and Timing Chains, Installing

• A revised camshaft adjuster is being installed as of November 2008. Identifying feature: To recognize the new adjuster: starting in November 2008 the exhaust camshaft adjuster 32A has a plastic cover.

=> [ Vehicles through 11.08 ]

=> [ Vehicles from 12.08 ]

Vehicles through 11.08

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)

• Sealant (D 176 501 A1)

Requirement:

• Transmission removed

• Flywheel removed

• Oil pan removed

• Sealing flange on the flywheel side removed

• Chain sprockets removed from the intermediate shaft

Procedure

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

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Installing the Timing Chain and the Chain Tensioner with Tensioning Plate for Intermediate Shaft Drive

- Set the crankshaft to Top Dead Center (TDC) cylinder 1. To do so, the milled crankshaft drive sprocket tooth - arrow - must align with the crankshaft bearing cap separating joint.

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

- Rotate the intermediate shaft so that the flattened side faces up.

- Install the timing chain onto the guide rail and mount it onto the crankshaft drive gear.

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

- Install the large sprocket onto the intermediate shaft.

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

The milled crankshaft drive sprocket tooth must align with the crankshaft bearing cap separating joint - arrow A -.

The tab on the large sprocket must align with the tab - arrow B - behind it.

- If large chain sprocket cannot be installed, rotate intermediate shaft slightly.

• Note direction of rotation of a used timing chain, refer to => [ Timing Chain Marks ] Chain Drive and Cylinder Block and Lubrication Overview.

- Install the small sprocket onto the intermediate shaft. Installation is possible in one position only.

- Install the intermediate shaft bolt - arrow - hand tight because the small sprocket must be removed one more time.

- Install the chain tensioner.

- Release the locking splines of the chain tensioner using a small screwdriver and press the tensioning rail against the chain tensioner.

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

Installing the Camshaft Timing Chain

Conditions

• The camshaft adjusters are installed

• The camshaft lobes - A - for cylinder 1 must face each other

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

- Remove the small sprocket. The large sprocket may not be removed.

- Route the chain between the tensioning rail and guide rail toward the control housing.

- Place the timing chain on the camshaft adjuster in such a way that the 2 individual copper colored chain links - C - align with the marks on the camshaft adjuster. It is possible that the intake camshaft adjust will have to be rotated slightly.

- Install the small sprocket into the timing chain. The mark - B - must align with the center copper colored chain link - A -.

- Install the small sprocket together with the timing chain onto the intermediate shaft. Installation is possible in one position only.

- Lock the vibration damper using (T10069).

- Tighten the new intermediate shaft bolt - arrow - to 60 Nm + 90° (1/4) additional turn. (The additional turn may be performed in several steps.)

- Check the position of the camshaft to the intermediate shaft one more time.

• The milled crankshaft drive sprocket tooth must align with the crankshaft bearing cap separating joint - arrow B -.

• The tab on the large sprocket must align with the tab - arrow C - behind it.

- Check the position of the copper color chain links - C - to the adjustment marks.

• After rotating the crank shaft, the copper color chain links no longer align with the adjustment markings.

- Apply sealant (D 176 501 A1) to the sealing surfaces on the sealing flange as illustrated.

• Note alignment pins in the cylinder block.

- Install sealing flange immediately.

- To do this, install all the bolts by hand and tighten them to 10 Nm.

- Install the sealing flange seal. Refer to => [ Crankshaft Sealing, Transmission Side ] Crankshaft Sealing, Transmission Side.

- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.

If replacing the seals in the camshaft front cover, refer to => [ Camshaft Front Cover Seal, Installing ] Service and Repair.

- Clean the sealing surfaces on the cover and on the cylinder head.

- Lubricate oil passage seal O-ring - 1 - and insert it in the cover.

- Make sure the alignment sleeves - 2 and 3 - are inserted.

- Install the seal - 4 - in the cover.

- Clean the old sealing compound from the 3 mm holes in the cylinder head gasket - arrows -.

- Fill the 3 mm holes in the cylinder head gasket with sealant (D 176 501 A1). Apply sealant (D 176 501 A1) to the sealing surfaces on the cover and install the cover immediately.

- Install the camshaft front cover bolts - arrows - and tighten lightly.

- Then tighten the M8 bolts => [ (Item 8) Bolt ] Service and Repair to 23 Nm and tighten the M6 bolts => [ (Item 2) Stud bolt ] Service and Repair to 8 Nm.

- Install the chain tensioner for the camshaft timing chain and tighten to 40 Nm.

- Rotate the crankshaft twice in engine rotation direction and check the valve timing again. Refer to => [ Vehicles through 11.08 ] Adjustments.

• After rotating the crankshaft, the copper color chain links no longer align with the adjustment marks.

- Install the cylinder head cover and intake manifold. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

Vehicles from 12.08

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)

• Sealant (D 176 501 A1)

Requirement:

• Transmission removed

• Flywheel removed

• Oil pan removed

• Sealing flange on the flywheel side removed

• Chain sprockets removed from the intermediate shaft

Procedure

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

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Install the Timing Chain and the Chain Tensioner with Tensioning Plate for Intermediate Shaft Drive

- Set the crankshaft to Top Dead Center (TDC) cylinder 1. To do so, the milled crankshaft drive sprocket tooth - arrow - must align with the crankshaft bearing cap separating joint.

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

- Turn the intermediate shaft so that the flattened side faces up.

- Install the timing change into the glide track and mount it on to the crankshaft.

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

- Install the large sprocket onto the intermediate shaft.

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

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

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

- If large chain sprocket cannot be installed, rotate intermediate shaft slightly.

• Note direction of rotation of a used timing chain, refer to => [ Timing Chain Marks ] Chain Drive and Cylinder Block and Lubrication Overview.

- Install the small sprocket onto the intermediate shaft. Installation is possible in one position only.

- Tighten the intermediate shaft bolt - arrow - hand tight because the small sprocket must be removed one more time.

- Install the chain tensioner.

- Release the locking splines of the chain tensioner using a small screwdriver and press the tensioning rail against the chain tensioner.

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

Install the Camshaft Drive Timing Chain

Conditions

• The camshaft adjusters are installed

• The camshaft lobes - A - for cylinder 1 must face each other

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

- Remove the small sprocket. The large sprocket may not be removed.

- Tighten the new intermediate shaft bolt - arrow - to 60 Nm + 90° (1/4) additional turn. (The additional turn may be performed in several steps.)

- Check the position of the camshaft to the intermediate shaft one more time.

• The milled crankshaft drive sprocket tooth must align with the crankshaft bearing cap joint - arrow B -.

• The tab on the large sprocket must align with the tab - arrow C - behind it.

- Check the position of the copper color chain links to the adjustment marks.

• After rotating the crankshaft, the copper color chain links no longer align with the adjustment markings.

- Apply sealant (D 176 501 A1) onto the clean sealing surfaces of the sealing flange as shown.

• Note the alignment pins in the cylinder block.

- Install sealing flange immediately.

- To do this, insert all the mounting bolts by hand and tighten them to 10 Nm.

- Install the seal in the sealing flange. Refer to => [ Crankshaft Sealing, Transmission Side ] Crankshaft Sealing, Transmission Side.

- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.

If replacing the seals in the camshaft front cover, refer to => [ Camshaft Front Cover Seal, Installing ] Service and Repair.

- Clean the sealing surfaces on the cover and on the cylinder head.

- Lubricate the oil passage seal O-ring - 1 - and insert it in the cover.