Valve Timing, Setting
Special tools, equipment, test and inspection devices; required accessories
- 3268 Camshaft ruler
- 3406 Counter-hold
- T10029 Spark plug connector tool
- VAG 1331 torque wrench (5 - 50 Nm)
- VAG 1332 torque wrench (40 - 200 Nm)
Procedure
With engine removed
Install roller chain and chain tensioner with tension bar:
- Set and check position of crankshaft in relation to intermediate shaft.
The ground tooth of drive gear -13- must be aligned with the bearing parting line (TDC cyl. 1).
- Install bolt without collar for sliding rail -2- and tighten to 10 Nm.
- Install sliding rail -2- with roller chain -1- and both sprockets -3- and -4- (note direction of travel of roller chain.
The mark on the sprocket for roller chain -4- must be aligned with notches -C- or -D- on the thrust washer.
- Release stop teeth in chain tensioner with a small screwdriver -A-.
- Press tension bar against chain tensioner and tighten chain tensioner to 10 Nm.
- Lock vibration damper in position with locking bracket 3406.
- Tighten sprockets 3 and 4 for intermediate shaft to 100 Nm.
- Remove locking bracket 3406.
- Check position of crankshaft in relation to intermediate shaft.
The ground tooth of drive gear -B- must be aligned with the bearing parting line (TDC cyl. 1).
Install camshaft roller chain and chain tensioner with tension bar:
- Set both camshafts to TDC cyl. 1.
- Align camshafts with camshaft guide 3268.
- Install bearing bolt for tension bar and tighten to 18 Nm.
- Install tension bar for chain tensioner (camshaft roller chain).
- Install bearing bolt with collar for sliding rail and tighten to 10 Nm.
Note: If the cylinder head is removed:
- Install cylinder head
- Push sliding rail onto bearing bolt. Insert short mounting screw with "D6" locking compound and tighten both bolts to 20 Nm.
- Place camshaft roller chain on intermediate shaft (note direction of travel).
- Mount camshaft sprocket and roller chain on camshaft for cylinder bank 1, 3 and 5 (long camshaft) and counter tighten by hand.
- Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4, and 6 and tighten by hand.
Note: Coat contact surfaces of the bolt heads with oil when installing.
- Remove camshaft guide 3268.
- Tighten mounting bolts for camshaft sprockets to 100 Nm.
Note: Hold camshaft -arrow- only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets.
- Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten mounting bolt to 10 Nm.
- Replace oil seal for sealing flange.
- Prepare cylinder head gasket for assembly.
- Coat sealing surface of cover piece with AMV 188 001 02.
- Coat O-ring for oil passage seal and insert in cover piece.
- Install cover piece, insert all mounting bolts and turn in opposite direction slightly.
- Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm.
- Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip.
- Rotate crankshaft two turns in direction of rotation of engine and check valve timing.
With engine installed, cylinder head removed
- Using mounting bolt for vibration damper, align crankshaft with mark for TDC cyl. 1 -arrow-.
If cylinder 1 is correctly at TDC position, it will be possible to see a slot -arrow- on intermediate shaft sprockets.
If the slot is not visible:
- Turn crankshaft one turn in direction of rotation of engine.
Note: If the crankshaft is turned with the cylinder head removed, a second mechanic must guide the camshaft roller chain by hand to prevent blocking.
- Set both camshafts to TDC of cyl. 1.
- Align camshafts with camshaft guide 3268.
- Prepare cylinder head gasket for assembly.
- Install cylinder head.
- Push sliding rail onto bearing bolt. Insert short mounting bolt with "D6" locking compound and tighten both bolts to 20 Nm.
- Mount camshaft sprocket with camshaft roller chain to camshaft for cylinder bank 1, 3 and 5 (long camshaft) and turn in opposite direction by hand.
- Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4 and 6 and turn in opposite direction by hand.
Note: Coat contact surfaces of the bolt heads with oil when installing.
- Remove camshaft guide 3268.
- Tighten mounting bolts for camshaft sprockets to 100 Nm.
Note: Hold camshaft -arrow- only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets.
- Coat sealing surface of sealing flange with AMV 188 001 02.
- Coat O-ring for oil passage seal and insert in cover piece.
- Install cover piece, insert all mounting bolts and turn in opposite direction slightly.
- Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm.
- Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip.
- Rotate crankshaft twice in engine travel direction and check timing.
Marking roller chains
- Mark roller chains before removal (e.g., put an arrow in direction of travel with paint).
Note: Do not mark the chain with a center punch, chisel, etc.