Cylinder Head Assembly: Adjustments
Valve Timing, Adjusting
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Locking Pins (T03006)
• Multipoint Socket (T10035)
• Counterhold Tool Touareg V10 (T10172)
• Camshaft Clamp (T40070)
• 2 M8 x 16 Bolts
Modifying the Counterhold Tool Touareg V10 (T10172) :
- Remove the adapters (T10172/1) and install 2 M8 x 16 bolts - A -.
• The valve timing must be adjusted if the camshaft sprockets were loosened during repairs or if the valve timing is not set.
Securing the Camshafts if the Valve Timing is Correct:
- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Chain Compartment Cover.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Lock the crankshaft for adjusting the valve timing. Refer to => [ To Check/Adjust Valve Timing ] Procedures.
- Install the camshaft clamp (T40070) as shown onto the camshafts and tighten the bolts to 20 Nm.
If the bolts could not be installed easily, attempt to rotate the exhaust camshaft at the recess using an open end wrench - A - (18 or 19 mm, depending on wrench width) slightly in the - direction of the arrow - in order to eliminate any play in the chain.
- Relieve the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the piston in the chain tensioner and the tensioning rail and press in the - direction of the arrow -.
- Secure the completely pressed in piston using the locking pin (T03006). The locking pin must be inserted until it stops.
Securing the Camshafts if the Valve Timing is Not Correct:
- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Chain Compartment Cover.
- Rotate the crankshaft to Top Dead Center (TDC) for cylinder 5, refer to => [ To Check/Adjust Valve Timing ] Procedures, however do not lock the crankshaft using the locking pin (T40069).
- Rotate the crankshaft so that the camshaft clamp (T40070) can be installed easily onto the camshafts as shown.
- Tighten the camshaft clamp (T40070) bolts to 20 Nm.
Removing the Adjuster and Sprocket from the Camshafts:
- Relieve the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the piston on the chain tensioner and the tensioning rail and press in the - direction of the arrow -.
- Secure the completely pressed in piston using the locking pin (T03006). The locking pin must be inserted until it stops.
- Remove the bolts - 1 and 4 - using the multipoint socket (T10035) and remove the adjuster - 2 - and sprocket - 3 -.
If necessary, the sprocket - 3 - must be pried off lightly using a screwdriver.
• Lock the crankshaft, refer to => [ Crankshaft, Locking ] Procedures if not yet secured. The crankshaft must only be rotated slightly around the TDC point for this. Otherwise there is a risk the valves rest on the pistons.
Valve Timing, Adjusting
• The crankshaft is secured by the locking pin (T40069)
• The camshafts are secured by the camshaft clamp (T40070)
• The chain tensioner is tensioned
- Place the adjuster - 2 - and sprocket - 3 - into the timing chain, place them onto the camshafts and hand tighten the new bolts - 1 and 4 -.
The adjuster and sprocket must still be able to be rotated, however they must not tilt.
• Make sure that the timing chain lies correctly in the guide and tensioning rails.
- Relieve the tension on the chain tensioner by pressing in the piston and pulling out the locking pin (T03006).
- Install the modified counterhold tool Touareg V10 (T10172) onto the sprocket - 4 - for the exhaust camshaft.
• A second mechanic is required for the following steps.
- Hold the timing chain at preload by pressing the counterhold tool Touareg V10 (T10172) in the - direction of the arrow -.
- Simultaneously tighten the bolt - 2 - fro the intake camshaft first and then the bolt - 3 - fro the exhaust camshaft to 60 Nm.
Then, tighten the bolts - 2 and 3 - an additional 90° (1/4) turn.
• When applying the additional torque of 90°, the timing chain must no longer be held at preload.
- Remove the camshaft clamp (T40070).
- Remove the locking pin (T40069).
- Rotate the crankshaft 2 revolutions in engine rotation direction and lock the crankshaft. Refer to => [ To Check/Adjust Valve Timing ] Procedures.
- Check the valve timing. Refer to => [ Valve Timing, Checking ] Testing and Inspection.
If the valve timing is not correct:
- Loosen the adjuster and sprocket bolts on the camshafts again and adjust the valve timing again (replace the camshaft bolts).
The rest of the installation follows the reverse of the removal procedures. When doing this note the following:
• Remove the locking pin (T40069) from the rear of the cylinder block and install the locking bolt.
• Fill the coolant system. Refer to => [ Draining and Filling ] Procedures.