Camshaft, Lifters and Push Rods: Adjustments
Valve timing, adjusting
Note:
^ (Install roller chain, work procedure possibly only with engine removed)
Special tools, testers and auxiliary items required
^ Adjustment tool T10332
^ Camshaft bar T10068 A
^ Counter-holder tool T10069
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
Not illustrated:
Special tools, testers and auxiliary items required
^ Sealant D 176 501
Work procedure
CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
^ Ensure sufficient clearance to all moving or hot components.
Note:
^ The following work sequence is described with engine removed. The adjustments required depend on how far the engine has been disassembled. Oil pan is removed and must only be installed after assembling sealing flange.
Install roller chain and chain tensioner with tensioning track for oil pump drive:
- First set crankshaft to TDC Cylinder 1. To do so, milled tooth of drive pinion - arrow - must align with bearing separating gap.
- Install both bolts without collar for glide track and tighten to 10 Nm.
- Now set oil pump shaft - 1 - with flat side - arrow - horizontal to marking - 2 - on oil pump.
Note:
^ For an already used roller chain, observe marking of direction of travel
- Connect glide track - 3 - on to both installed bolts. Now place drive chain - 2 - on to crankshaft toothed gear and on to drive pinion - 1 - and place it on to oil pump shaft with chain - 2 - running straight. Marking - 4 - in drive pinion - 1 - must align with one on oil pump.
- Release lug - arrow - in chain tensioner - 5 - using a small screwdriver. Press tensioning arm together with chain tensioner and bolt it tightly on cylinder block.
- If cylinder head has been removed, install it now.
- Camshaft bar T10068 A must be inserted in both shaft grooves.
- Now guide drive chain for camshafts and high pressure pump through opening in cylinder head or cylinder head gasket from above.
- Insert small drive pinion with installed chain into recess - arrow - and bolt it on hand-tight.
- Lock vibration damper using counter-holder tool T10069.
- With a new mounting bolt, tighten both chain sprockets on oil pump shaft to 60 Nm, then turn an additional 1/4 (90°). Only use bolts with strength category 10.9.
Note:
^ Be aware that all chain sprocket securing bolts must be replaced.
Install drive chain for camshafts and high pressure pump. Cylinder head has been removed:
- Insert glide track - 2 - through opening in cylinder head and install it tightly with mounting bolts - 1 - and - 3 -.
- Insert tensioning track - 4 - and install tightly on cylinder block with bearing bolt - 5 - .
- Coat needle bearing on inside in drive pinion - 2 - with clean engine oil and insert it with chain installed into its thrust bearing. Make sure that notch - arrow - points upward and chain runs tautly along on glide track. Now slide in bearing shaft - 3 -.
- Make sure that alignment bushing - 1 - is inserted. It is used to secure adjustment tool.
Vehicles without mechanical vacuum pump:
- Also secure position of drive pinion for high pressure pump using adjustment tool T10332.
Vehicles with mechanical vacuum pump:
- Also secure position of drive pinion for high pressure pump using adjustment tool T10363. Marking - A - on high pressure drive camps must be at top.
Continuation for all vehicles:
First install camshaft adjuster for intake camshaft as follows:
Note:
^ Both camshaft adjusters (identification: "24E" on intake side and "32A" on exhaust side) can only bolted in one position on camshaft mountings - arrows - due to an alignment pin.
- Now turn sensor wheel - 1 - on removed intake camshaft adjuster clockwise - arrow - as far as stop and hold the adjuster in this position. Adjuster must be able to be inserted easily on intake camshaft with camshaft roller chain installed tautly and be tightened hand-tight.
- Make sure that camshaft roller chain to drive pinion of high pressure pump does not sag.
- Arrow - 1 - on camshaft adjuster "24E" must align with notch - 2 - of control housing. Markings on control housing
- Now count exactly 16 rollers on timing chain to right from tooth with arrow - 1 - aligning with notch - 2 -. Mark this roller with a color marker.
Note:
^ Exhaust camshaft adjuster is locked in the rest state. Therefore sensor wheel cannot be rotated when adjusting the valve timing. If locking mechanism in rest state is not engaged (locked) turn adjuster in both directions by hand until it locks. If that is not possible, replaced camshaft adjuster.
- Now insert exhaust camshaft adjuster "32A" with tooth at arrow marking - 1 - into camshaft roller chain so that the exact, previously counted 16 rollers lie between marking "24E" and "32A" and markings - 1 - and - 2 - align. Markings on control housing
- Exhaust camshaft adjuster must be able to be inserted easily on exhaust camshaft and be tightened hand-tight.
- Remove Adjustment Tool T10332 or Adjustment Tool T10363 from bearing shaft.
- Remove camshaft bar T10068 A.
- Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
- Check adjustment once again.
If markings match:
- Secure respective camshaft to be tightened using an open-end wrench (27 mm) - arrow -.
Note:
^ Camshaft bar T10068 A must not be inserted during this process.
^ Be aware that all chain sprocket securing bolts must be replaced.
- Tighten new securing bolts - 3 - for intake and exhaust camshaft adjusters - 4 - and - 2 - to 60 Nm plus an additional 1/4 turn (90°).
Now sealing flange can be assembled as follows:
- First spray a sealant bead of Sealant D 176 501 into corners of cylinder block / cylinder head - arrows - so that the 3 mm bores in cylinder head gasket are filled.
- Apply Sealant D 176 501 on to clean sealing surfaces of sealing flange as shown.
Note:
^ Note alignment pins in cylinder block.
- Install sealing flange immediately.
- To do this, insert all mounting bolts by hand and tighten to 10 Nm.
- Now install sealing ring for crankshaft in sealing flange.
- Now install oil pan.
Replace sealing rings in cover piece as required.
- Coat sealing surface of cover piece facing cylinder head with Sealant D 176 501.
- Install cover piece, insert all mounting bolts and tighten to 8 Nm.