Timing Chain: Service and Repair
Oil Pump Drive Timing Chain, Installing
• Procedure is only possible when the engine is removed from the engine compartment!
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 mechanical vacuum pump)
• Adjustment Tool (T10363) (with mechanical vacuum pump)
• Sealant (D 176 501 A1)
Requirements
• Engine is removed
• Drive plate is removed
• Oil pan is removed
• Sealing flange is removed
• Cylinder head cover is removed
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 procedure is described with the engine removed. The adjustments required depend on how far the engine has been disassembled. The oil pan is removed and must only be installed after installing the sealing flange.
Install the timing chain and the chain tensioner with tensioning rail for the oil pump drive:
- Set the crankshaft to Top Dead Center (TDC) cylinder 1. To do so, the milled tooth on the crankshaft drive sprocket - arrow - must align with the crankshaft bearing cap joint.
- Install both locating pins without collars for the guide rail and tighten them to 10 Nm. Place the guide tail on the 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 a used timing chain, refer to => [ Identifying the Timing Chain ] Description and Operation.
- Install the timing chain into the guide rail and mount it onto the crankshaft drive sprocket.
- Install the large sprocket into the timing 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 timing chain runs completely straight in the guide rail from the crankshaft to the oil pump shaft.
• The milled crankshaft drive sprocket tooth must align with the crankshaft bearing cap joint - arrow A -.
• The tab on the large 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 of the chain tensioner - A - 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.
- If the cylinder head was removed, install it now, refer to => [ Cylinder Head ] Service and Repair.
- Install the (T10068 A) into both camshaft grooves.
- Guide the timing chain through the opening in the cylinder head or cylinder head gasket from above.
- Install the small sprocket with the chain installed into the recess - arrow - and install the bolt hand tight.
- Lock the vibration damper using the (T10069).
- Using a new bolt, tighten both sprockets to the oil pump shaft. Tighten the bolt 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 install the bolts - 1 and 3 -.
- Install the tensioning rail - 4 - and install the pivot pin - 5 -.
Without a Mechanical Vacuum Pump
- Lubricate the needle bearing on the inside of the high pressure pump 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 alignment bushing - 1 - is inserted. It is used to secure the (T10332).
- Secure the position of the high pressure pump drive pinion using the (T10332).
With a Mechanical Vacuum Pump
- Install the high pressure pump drive pinion - 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 the alignment bushing - 5 - is inserted. It is used to secure the (T10363).
- Secure the position of the high pressure pump drive pinion using the (T10363). The mark - A - on the high pressure pump drive pinion must be at the top.
Continuation for All
- Install the camshaft adjusters, 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.