Installing (Adjusting Valve Timing)

Installing (adjusting valve timing)

Note: Crankshaft must not be at TDC when camshaft is rotated, otherwise valves can contact pistons and cause damage.





- Replace camshaft sprocket bolts -1- and securing plates -2-.
- Oil threads and bolt head contact surfaces of camshaft sprocket bolts.
- Tighten bolts until camshaft sprockets can still just be turned, but do not tilt axially.
- Make sure that securing plates seat properly on camshafts.

Before installing toothed belt, check that crankshaft and camshafts are in TDC position for No. 5 cylinder





^ Larger holes (arrows) in securing plates on camshaft sprockets should point inward...





^ ... and clamping bolt 3242 must be screwed in.





- Install toothed belt first onto- crankshaft sprocket -5-, eccentric wheel - 4-, tensioning roller -6-, left camshaft sprocket -3- and coolant pump -2-
- Then install toothed belt onto right camshaft sprocket -1-.





- Turn tensioning lever twice in direction of (arrow) with torque 40 Nm to pre-tension toothed belt.

Note: For clarity, engine is shown here and in following illustrations with bracket for torque reaction mount removed.





- Place flat sides of a 5 mm Allen key between tensioning lever -1- and piston -2- of tensioning element.

Note: Use a "3/8" 1/4" adapter when applying tensioner 8 4 wrench T40009.





- Pre-tension toothed belt by turning eccentric wheel in direction of arrow using tensioner wrench T4009 and V.A.G 1783 with reversible ratchet VAS 5122. Apply torque and hold.
^ Pre-tensioning torque - 6 Nm

- Tighten eccentric wheel.
^ Tightening torque - 45 Nm

Note: Make sure that adjustment is not altered when tightening bolt.





- Install camshaft clamp T40005 onto securing plates of the two camshafts.
^ Push on camshaft clamp as far as it will go.

- Tighten camshaft sprocket bolts.

Note: Camshaft clamp T40005 is used to counterhold sprockets.

- Remove camshaft clamp T40005.
- Remove 5 mm Allen key.





- Using an 8-mm hex socket key, turn tensioning lever in direction of arrow until locking pin T40011 can be pulled out.
- Remove crankshaft clamping bolt 3242.
- Turn crankshaft two rotations in normal direction of rotation until it is set to TDC position of No. 5 cylinder again.





^ Larger holes (arrows) in securing plates on camshaft sprockets should point inward.





- Check distance -a- between tensioning lever and belt tensioner housing.
^ Distance a = 5.0 + 1.0 mm

Note: Repeat adjustment if distance -a- is not correct.





- To check valve timing setting, screw clamping bolt 3242 into hole on upper section of sump once again.





- Check positions of camshafts with camshaft clamp T40005.

Note: If it is not possible to insert camshaft clamp, repeat adjustment.

- Remove camshaft clamp T40005 from both cylinder heads.
- Remove clamping bolt 3242.
- Screw plug for TDC marking with new seal into upper section of sump.

Remaining installation steps are carried out in reverse sequence - note following points-.

Notes:
^ Replace gaskets, seals and O-rings.
^ Secure all hose connections with correct hose clamps (same as original equipment) See parts catalog.
^ Remove any traces of oil or grease on hose connections and hoses for charge air system before installing. Do not apply lubricant.

- Install anti-roll bar
- Install ribbed belt
- Installing lock carrier with attachments:
Refer to Body and Frame
- Installing front bumper
- Install air filter housing.
- Fill up with coolant.

Note:
^ Drained-off coolant may only be used again if original cylinder head and cylinder block are reinstalled.
^ Coolant must not be used again if it is dirty.

- Adjust headlights:





Tightening torques