Camshaft, Lifters and Push Rods: Adjustments
Valve timing, adjusting
Installation of the roller chain work sequence is only possible when the engine is removed from the engine compartment.
Special tools equipment
^ 3242 Clamping bolt
^ T10068 Camshaft bar
^ T10069 Counter-holder
^ VAG 1331 Torque wrench (5...50 Nm)
^ VAG 1332 Torque wrench (40...200 Nm)
^ LSE020 100 AS Silicone remover
^ D 188 800 A1 Sealing compound
^ 3.5 mm diameter drill bit
Work sequence
Note:
^ The following work sequence can only be performed when the engine is removed from the engine compartment. The adjustments required depend on how far the engine has been stripped down.
^ Note direction of rotation of used chains, Refer to Timing Chain, Service and Repair.
^ Roller chains must run completely straight in guide and tensioner rails.
^ Ensure that all chain sprocket securing bolts are replaced.
^ Turn crankshaft to TDC No. 1 cylinder.
Mark -1- must align with cylinder block joint -2-.
^ Remove sealing plug from left side of cylinder block.
^ Screw clamping bolt 3242 into hole so that crankshaft is secured against turning.
^ Position camshafts in cylinder head to TDC No. 1 cylinder.
Camshaft bar T10068 must engage in both shaft grooves.
Note:
^ If the camshaft bar cannot be engaged in the camshafts, turn camshafts in direction of rotation past TDC No. 1 Cyl. and then back to TDC No. 1 Cyl.
^ If necessary, turn camshafts to the correct position using a 32 mm open jaw wrench. Camshaft bar T10068 must not be installed during this process.
Installing roller chain (crankshaft/intermediate shaft)
^ Install intermediate shaft.
^ Install roller chain (crankshaft/intermediate shaft) -1- together with intermediate shaft sprocket -2-.
^ Copper link (arrow -A-) must align with cylinder block joint -3-.
^ Copper link (arrow -B-) must be positioned on top of intermediate shaft chain sprocket-2-.
^ Install chain sprocket (intermediate shaft/camshaft adjuster) -4- onto intermediate shaft chain sprocket -2-.
^ Tighten new bolt -5- for chain sprocket hand-tight.
^ Install guide rail -6-.
^ Install chain tensioner -7- with locking plate.
^ Tightening torque: 8 Nm
^ Release lock for chain tensioner -7-.
Installing roller chain (intermediate shaft/camshaft timing adjuster cylinder bank 1)
Note: The camshaft timing adjuster can be turned in two directions. Please ensure, when installing, that the sender wheel for the Hall sender is turned on to the respective limit stop.
Intake camshaft timing adjuster for cylinder bank 1
^ Turn Hall sender wheel -1- in direction of arrow on to limit stop.
Exhaust camshaft adjuster for cylinder bank 1
^ Turn Hall sender wheel -1- in direction of arrow on to limit stop.
^ Install roller chain (intermediate shaft/camshaft adjuster cylinder bank 1) -1- together with camshaft adjusters.
2. Intake camshaft timing adjuster, Identification: B1 and E7
3. Exhaust camshaft timing adjuster, Identification: B1 and AS
Copper link (arrow -A-) must be positioned on top of intermediate shaft chain sprocket-4-.
Copper link of camshaft roller chain (arrow) must align with arrow -1on intake camshaft adjuster.
Copper link of camshaft roller chain (arrow) must align with arrow -1on exhaust camshaft adjuster.
^ Tighten new bolts for camshaft adjuster -5- hand tight.
^ Install guide rail -6-.
^ Install tensioning rail -7-.
Installing roller chain (intermediate shaft/camshaft timing adjuster cylinder bank 2)
Note: The camshaft timing adjuster can be turned in two directions. Please ensure, when installing, that the sender wheel for the Hall sender is turned on to the respective limit stop.
Intake camshaft adjuster for cylinder bank 2
^ Turn Hall sender wheel -1- in direction of arrow on to limit stop.
Exhaust camshaft adjuster for cylinder bank 2
^ Turn Hall sender wheel -1- in direction of arrow on to limit stop.
^ Install roller chain (intermediate shaft/camshaft timing adjuster cylinder bank 2) -1- together with camshaft adjusters.
2. Intake camshaft timing adjuster, Identification: B2 and E7
3. Exhaust camshaft timing adjuster, Identification: B2 and AS
Copper link (arrow -A-) must be positioned on top of intermediate shaft chain sprocket-4-.
Note: The copper links of the camshaft roller chain for cylinder bank 2 are visible from the back.
Copper link of camshaft roller chain (arrow) must align with arrow -1on intake camshaft adjuster.
Copper link of camshaft roller chain (arrow) must align with arrow -1on exhaust camshaft adjuster.
^ Tighten new bolts of camshaft adjuster-5-.
^ Install guide rail -6-.
^ Install tensioning rail -7-.
^ Install limit stop for chain tensioner -8-.
Torque setting: 20 Nm
^ Install chain tensioner-9-.
Torque setting: 9 Nm
^ Release lock on chain tensioner -9-.
^ Remove clamping bolt 3242.
^ Install sealing plug in cylinder block.
Torque setting: 20 Nm
^ Remove camshaft bar T10068.
^ Lock vibration damper with counter-holder T10069.
^ Tighten new securing bolt for intermediate shaft sprocket -1- to 60 Nm + 90°(1/4 turn). (Turning further can be performed in several steps.)
^ Counter-hold camshafts using a 32 mm open jaw wrench.
Note: Counter-hold only with 32 mm open jaw wrench on camshaft (arrow). Camshaft bar T10068 must not be installed when sprockets are loosened or tightened.
^ Tighten new securing bolts for camshaft timing adjuster -2- to 60 Nm + 90°(1/4 turn). (Additional turning can be performed in several steps.)
^ Install flywheel/drive plate sealing flange.
^ Replace seal on flywheel/drive plate sealing flange.
Installing cover (cylinder banks 1 and 2)
^ Clean sealing surfaces and sealing groove -2- in cover -1- and sealing surfaces of flywheel/drive plate sealing flange using silicone remover LSE 020 100 A3. Surfaces must be free of oil and grease.
Note: A sealing nipple -4- is installed according to version of cover piece.
^ Lubricate O-ring for oil passage seal -3- (cylinder bank 1) and insert into cover-1-.
^ Cut through nozzle (along forward marking) of sealant D 176 501 A1 (diameter of nozzle approx. 2 mm).
Note: Observe sealant expiration date.
^ Apply sealant as shown to clean sealing surface of cylinder head cover and on sealing surface of rear sealing flange -2-. Sealing compound bead must be: approx. 2 mm thick and run on inside of bolt holes (arrows).
Note: The cover must be installed within 5 minutes of applying the sealing compound.
Cylinder bank 1
Note: When installing, ensure that the sealing compound bead is not interrupted.
^ Install cover piece and press on tightly into position (arrow -A-).
^ Tighten bolt -3- hand tight.
^ Press cover piece on tightly into position (arrow -B-).
^ Tighten bolt -4- hand tight.
^ Then, tighten bolts in sequence indicated (Items 1 to 10) and note different bolt lengths.
Tightening torque: 10 Nm
^ Remove excess sealant
Cylinder bank 2
Note: When installing, ensure that the sealing compound bead is not interrupted.
^ Install cover piece and press on tightly into position (arrow -A-).
^ Tighten bolt -3- hand tight.
^ Press cover piece on tightly into position (arrow -B-).
^ Tighten bolt -4- hand tight.
^ Then, tighten bolts in sequence indicated (Items 1 to 9) and note different bolt lengths.
Tightening torque: 10 Nm
^ Remove excess sealant
Cylinder bank 1
^ Install camshaft roller chain tensioner (arrow).
Tightening torque: 40 Nm
Cylinder banks 1 and 2
^ Install cylinder head cover.