Installing Timing Chains For Intermediate Shaft Drive and Camshaft Drive

VAS PC Installing timing chains for int...
Installing timing chains for intermediate shaft drive and camshaft drive
Special tools and workshop equipment required

 Camshaft bar -T10068 A-
 Counterhold tool -T10069-
 Torque wrench -V.A.G 1331-
 Torque wrench -V.A.G 1332-
 Sealant -D 176 501 A1-
Procedure
Caution
When doing any repair work, especially in the engine
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compartment, pay attention to the following due to the

cramped conditions:
 Route all the various lines (e.g. for fuel, hydraulics,
activated charcoal filter system, coolant and refrigerant,
brake fluid and vacuum) and electrical wiring in their
original positions.
 To avoid damage to lines/wiring, ensure sufficient
clearance to all moving or hot components.
Note
The following procedure is only possible and described with
engine removed. You can start with adjustments at the relevant
point, depending on how far the engine has been dismantled. The
sump is removed and may only be fitted after installing the sealing
flange.
Install timing chain and chain tensioner with tensioning plate

for intermediate shaft drive:
– First set crankshaft to TDC No. 1 cylinder.
For this, the ground down tooth of drive
sprocket -arrow- must align with main
bearing joint.
– Install both pins without collar for guide rail

and tighten to 10 Nm. Fit guide rail on
studs.
– Turn intermediate shaft with flattened side

upwards.
– Insert timing chain into guide rail and place

on crankshaft.
– Insert large chain sprocket into timing chain

so that lug on chain sprocket aligns with
marking behind on cylinder block -arrow B-.
– Fit chain sprocket onto intermediate shaft.
When installing, ensure that timing chain runs

completely straight in guide rail from crankshaft
to intermediate shaft.
 Ground tooth of drive sprocket must align

with main bearing joint -arrow A-.
 Lug on chain sprocket of intermediate shaft
must align with marking behind -arrow B-.
– If large chain sprocket cannot be fitted, turn

intermediate shaft slightly.
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Note
If timing chain has already been used, note
marking for direction of rotation.
– Fit small chain sprocket of intermediate

shaft. Installation is only possible in one
position.
– Tighten bolt -arrow- hand-tight only as

small chain sprocket has to be taken off
again.
– Now install chain tensioner.
– To do this, release locking teeth of chain

tensioner -A- with a small screwdriver and
press tensioning plate against chain
tensioner.
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– Install chain tensioner in this position and

tighten to 8 Nm -arrows-.
Installing timing chain for camshaft drive:
Prerequisite
 The camshaft adjusters are installed
 Cams -A- of cylinder 1 must face each
other.
 Crankshaft is positioned at TDC
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– Insert camshaft bar -T10068 A- in both

shaft grooves.
– Remove small chain sprocket on

intermediate shaft. The large chain
sprocket must not be pulled off.
– Route chain between tensioning bar and

guide rail in direction of valve timing
housing.
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– Fit timing chain onto camshaft adjuster

such that 2 individual copper-coloured
chain links -4- align with markings on
camshaft adjuster -3- and with markings on
valve timing housing -5-. Markings on valve
timing housing → Fig.
– Fit small chain sprocket of intermediate

shaft into timing chain. Marking -2- must
align with middle copper-coloured chain link
-1-.
– Fit small chain sprocket with timing chain

attached onto intermediate shaft.
Installation is only possible in one position.
– Lock vibration damper using counterhold -

T10069-.
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– Tighten new securing bolt for intermediate

shaft chain sprockets -arrow- to 60 Nm +
90° (1/4 turn further). (Further turning can
be done in several steps.)
– Check position of crankshaft to

intermediate shaft once again.
 Ground tooth of drive sprocket must align

with main bearing joint -arrow B-.
 Lug on chain sprocket of intermediate shaft

must align with marking behind -arrow C-.
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– Check position of copper coloured chain

links to adjustment markings.
Note
The copper coloured chain links no longer
align with the adjustment markings once the
crankshaft has been turned.
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– Apply sealant -D 176 501 A1- onto clean

sealing surface of sealing flange as shown.
Note
Observe dowel pins in cylinder block.
– Immediately install sealing flange.
– Insert all securing bolts by hand and tighten

to 10 Nm.
– Now install oil seal for crankshaft in sealing

flange → Chapter.
– Now install sump → Chapter.
If seals in cover are to be renewed → Chapter.
– Clean sealing surface on cover and cylinder

head.
– Lubricate O-ring for oil channel seal -1- and

insert in cover.
– Check that dowel sleeves -2- and -3- are

inserted.
– Insert O-ring -4- in cover.
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– Remove old sealant from 3 mm holes in

cylinder head gasket -arrows-.
– Fill 3 mm holes in cylinder head gasket with

sealant -D 176 501 A1-. Coat sealing
surfaces of cover with sealant -D 176 501
A1- and install cover without delay.
– First insert all securing bolts -arrows- and

tighten lightly.
– Then tighten M8 securing bolts to 23 Nm

and then tighten M6 securing bolts to 8 Nm.
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– Install chain tensioner for camshaft timing

chain -arrow- and tighten to 40 Nm.
– Turn crankshaft two full turns in direction of

engine rotation and check valve timing
again → Chapter.
Note
The copper coloured chain links no longer
align with the adjustment markings once the
crankshaft has been turned.
– Install cylinder head cover and intake

manifold → Chapter.
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Installing Timing Chains For Intermediate Shaft Drive and Camshaft Drive

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VAS PC Installing timing chains for int...

Special tools and workshop equipment required

3/19/2016 1:01:59 PM Page 1 of 11

compartment, pay attention to the following due to the

Install timing chain and chain tensioner with tensioning plate

– Install both pins without collar for guide rail

– Turn intermediate shaft with flattened side

– Insert timing chain into guide rail and place

– Insert large chain sprocket into timing chain

– Fit chain sprocket onto intermediate shaft.

When installing, ensure that timing chain runs

 Ground tooth of drive sprocket must align

– If large chain sprocket cannot be fitted, turn

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– Fit small chain sprocket of intermediate

– Tighten bolt -arrow- hand-tight only as

– Now install chain tensioner.

– To do this, release locking teeth of chain

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– Install chain tensioner in this position and

Installing timing chain for camshaft drive:

 Crankshaft is positioned at TDC

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– Insert camshaft bar -T10068 A- in both

– Remove small chain sprocket on

– Route chain between tensioning bar and

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– Fit timing chain onto camshaft adjuster

– Fit small chain sprocket of intermediate

– Fit small chain sprocket with timing chain

– Lock vibration damper using counterhold -

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– Tighten new securing bolt for intermediate

– Check position of crankshaft to

 Ground tooth of drive sprocket must align

 Lug on chain sprocket of intermediate shaft

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– Check position of copper coloured chain

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– Apply sealant -D 176 501 A1- onto clean

– Immediately install sealing flange.

– Insert all securing bolts by hand and tighten

– Now install oil seal for crankshaft in sealing

– Now install sump → Chapter.

If seals in cover are to be renewed → Chapter.

– Clean sealing surface on cover and cylinder

– Lubricate O-ring for oil channel seal -1- and

– Check that dowel sleeves -2- and -3- are

– Insert O-ring -4- in cover.

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– Remove old sealant from 3 mm holes in

– Fill 3 mm holes in cylinder head gasket with

– First insert all securing bolts -arrows- and

– Then tighten M8 securing bolts to 23 Nm

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– Install chain tensioner for camshaft timing

– Turn crankshaft two full turns in direction of

– Install cylinder head cover and intake

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