Valve Timing, Installing and Adjusting
Valve timing, adjusting
Special tools and equipment
- T10068 Camshaft bar
- T10069 Counter support
- VAG 1331 Torque wrench (5-50 Nm)
- VAG 1332 Torque wrench (40-200 Nm)
- AMV 174 004 01 Sealing compound
- AMV 188 001 01 Sealing compound
Work sequence
CAUTION:
When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
- Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.
Note: The following work sequence is described for an engine after removal. Start with the adjustments at the relevant position depending on how far the engine has been disassembled
Install roller chain and chain tensioner with tensioning plate for intermediate shaft drive:
- Adjust position of crankshaft relative to intermediate shaft. To position: Align ground-down tooth of drive chain sprocket -B- with mounting joint (TDC cyl. 1).
- Install both bolts without collar for guide rail -2- and tighten to 10 Nm.
Note: Observe direction of rotation marks of used roller chain, Refer to Engine, disassembling and assembling, See Fig 1
- Install guide rail -2- with roller chain -1- and both chain sprockets -3- and -4-. Marking on sprocket -4- for roller chain must align with notch -C- or -D- on thrust washer of intermediate shaft.
During installation make sure that the roller chain runs completely straight in the guide plate from the crankshaft to the intermediate shaft.
- Tighten chain sprockets -3- and -4- on the intermediate shaft by hand.
Note: Please observe that all chain sprocket securing screws/bolts must be replaced.
- Install chain tensioner on opposite side.
- Release locking splines of chain tensioner -A- with a small screwdriver and tensioning plate pressed against chain tensioner.
- Install chain tensioner in this position and tighten to 8 Nm.
- Lock vibration damper with counter support T10069.
- Tighten new securing bolts of chain sprocket -3- and -4- for intermediate shaft to 60 Nm + 90° (1/4 turn - turning further can be done in several stages).
- Remove counter support T10069.
- Check position of crankshaft -B- to intermediate shaft -C- or -D- once again.
- Set engine again to TDC cyl. 1
Install roller chain for camshaft drive:
- Position camshafts installed in cylinder head to TDC cylinder 1
Note: If necessary use 32 mm open end wrench to turn camshafts -arrows- to the correct position. The camshaft bar T10068 must not be fitted when doing this.
It must be possible to insert camshaft bar T10068 into both shaft slots.
Note: If the cylinder head is removed, Refer to Cylinder Head, Service and Repair, Cylinder Head, Removing and Installing
- Place camshaft roller chain on intermediate shaft chain sprocket.
- Guide chain between tensioning rail and guide rail toward control housing.
- First install intake camshaft timing adjuster along with fitted camshaft roller chain.
- Position both camshaft timing adjusters (identification: 24E on inlet side and 32A on exhaust side) on the camshaft mountings -arrows-.
Note: The exhaust camshaft timing adjuster-1- can be turned in two directions. When installing, ensure that the sensor wheel -2- for the CMP sensor -G163- is turned onto limit stop in direction of -arrow-. The distance between the two ground-down teeth of the intake and exhaust camshaft timing adjusters (markings 24E and 32A) must be exactly 16 rollers of the camshaft roller chain
- Install exhaust camshaft timing adjuster with fitted camshaft roller chain. Marks -A and B- on camshaft timing adjusters must align with notches -arrows- on control housing -C-.
- Tighten new securing bolts for camshaft timing adjuster hand tight.
- Check distance between tooth -1- and tooth -2- of camshaft timing adjuster. It must be exactly 16 rollers of camshaft roller chain.
- Remove camshaft bar T10068.
- Turn crankshaft two full turns in engine direction of rotation and check valve timing, Refer to Timing Components, Service and Repair
Note: When the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand instead of with the chain tensioner.
If the marks do not align:
- Repeat timing adjustment.
If the marks align:
- Hold camshaft to be tightened with a 32 mm open end wrench -arrow-.
Note: The camshaft bar T10068 must not be fitted when doing this.
- Tighten new securing bolts -3- for intake and exhaust camshaft timing adjusters -4 and 2- to 60 Nm + 90°(1/4 turn - turning further can be done in several stages).
- Coat sealing surfaces of flywheel/drive plate sealing flange with sealing compound AMV 188 001 02 and install. Tighten securing bolts to 8 Nm.
- Replace flywheel/drive plate sealing flange.
- Remove old sealing compound from 3 mm holes in cylinder head gasket -arrows-.
- Fill 3 mm holes in cylinder head gasket with sealing compound AMV 174 004 02.
Note: When the cylinder head is installed the holes in the cylinder head gasket are only half visible.
- Coat sealing surface of cover with sealing compound AMV 188 001 02.
- Lubricate O-ring for oil channel seal and insert into cover together with seal ring.
- Install cover, insert all securing bolts and tighten lightly.
- First tighten M8 securing bolt to 23 Nm then M6 securing bolts to 8 Nm.
- Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
- Turn crankshaft two full turns in engine direction of rotation and check valve timing.
- Install cylinder head cover and intake manifold, Refer to Timing Cover, Service and Repair
- Check camshaft adjustments.