Cylinder Head Assembly: Adjustments
Valve Timing, Adjusting
Special tools, testers and auxiliary items required
• Camshaft bar (T10068 A)
• Counter holder tool (T10069)
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
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 (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
• The following procedure is only possible with the engine removed and is only described that way. The adjustments required depend on how far the engine has been disassembled. The oil pan is removed and must only be installed after installing the sealing flange.
Install the intermediate shaft roller chain and chain tensioner with tensioning rail for the intermediate shaft drive:
- Adjust the position of the crankshaft relative to the intermediate shaft. The milled tooth on the crankshaft drive gear - B - must align with the main bearing joint (Top Dead Center (TDC) cylinder 1).
- Install both locating pins without collars for the guide rail - 2 - and tighten to 10 Nm.
• Note the direction of rotation of the used chains. Refer to => [ Roller Chain, Marking ] Service and Repair.
- Install the guide rail - 2 - with the intermediate shaft roller chain - 1 - and both intermediate shaft chain sprockets - 3 and 4 -.
• Roller chain marking on the chain sprocket - 4 - must align with notch - C or D -.
During the installation make sure that the intermediate shaft roller chain runs completely straight in the guide rail from the crankshaft to the intermediate shaft.
- Tighten the intermediate shaft bolt for the chain sprockets - 3 and 4 - by hand.
• Be aware that all chain gear bolts must be replaced.
- Install the chain tensioner on the opposite side.
- Release the locking splines of the chain tensioner - A - with a small screwdriver and tensioning rail pressed against chain tensioner.
- Install the chain tensioner in this position and tighten the bolt it to 8 Nm.
- Lock the vibration damper using the (T10069).
- Tighten the new bolt for the intermediate shaft chain sprockets - 3 and 4 - to 60 Nm + 90° (1/4 turn). (The additional turn may be performed in several steps.)
- Remove the (T10069).
- Check the position of the crankshaft - B - to the intermediate shaft - C or D - once again.
- Set the engine again to TDC cylinder 1.
Install the camshaft roller chain:
- Position the camshafts in the cylinder head to TDC cylinder 1.
• If necessary use a 32 mm open end wrench to turn the camshafts - arrow - to the correct position. The (T10068A) must not be installed during this process.
- The (T10068A) must engage in both camshaft grooves.
• If the cylinder head is removed, install it. Refer to => [ Cylinder Head ] Cylinder Head.
- Place the camshaft roller chain on the intermediate shaft chain sprocket.
- Route the chain between the tensioning rail and guide rail toward the control housing.
• The (T10068A) remains installed.
• Both camshaft adjusters (identification: "24E" on the intake side and "32A" on the exhaust side) can only installed in one position on the camshaft mountings - arrows - by an alignment pin.
• The distance between the intake and exhaust camshaft adjuster markings " 24E" to "32A" amounts to exactly 16 rollers of the camshaft roller chain.
- Now turn sensor wheel - 1 - on intake camshaft adjuster clockwise in the - direction of the arrow - until it stops and hold the adjuster in this position.
Adjuster must be able to be inserted easily on the intake camshaft with the camshaft roller chain installed tautly and be tightened hand tight.
• If the intake camshaft adjuster is attached to the camshaft, the adjuster must be rotated left accordingly with the chain sprocket and then the camshaft roller chain must be routed.
- Ensure the camshaft roller chain rests against the guide rail - 1 - tautly and does not hang through.
- The arrow - 1 - on camshaft adjuster "24E" must align with the notch - 2 - on the control housing. For the markings on the control housing, refer to => [ Control Housing Markings with Multi-Port Injection
(MPI) Engines ] Valve Timing, Checking.
- Now count exactly 16 rollers on the camshaft roller chain to the right from the tooth with the arrow - 1 - aligning with the notch - 2 -. Mark this roller with a colored mark.
• The exhaust camshaft adjuster is locked in the rest state. Therefore the sensor wheel cannot be rotated when adjusting the valve timing. If the locking mechanism in the rest state is not engaged (locked) turn the adjuster in both directions by hand until it locks. If that is not possible, replaced the camshaft adjuster.
- Install the exhaust camshaft adjuster "32A" positioned in this way with tooth at the arrow mark- 1 - into the camshaft roller chain so that the exact, previously counted 16 rollers lie between the markings "24E" and "32A" and the markings - 1 and 2 - align.
- The exhaust camshaft adjuster must be able to be inserted easily on the exhaust camshaft and the bolt be tightened hand tight.
- Check the position of both camshaft adjusters in positions - A and B - with the 16 rollers between - 1 and 2 - again for the correct adjustment.
- Remove the (T10068A).
- Rotate the crankshaft twice in direction of engine rotation and check the valve timing. Refer to => [ Valve Timing, Checking ] Valve Timing, Checking.
• When rotating the crankshaft, the tensioning rail must be pressed by hand against the camshaft roller chain at the chain tensioner, so that the camshaft roller chain does not jump over!
If the markings match:
- Hold the respective camshaft tightly with an 32 mm open end wrench - arrow -.
• The (T10068A) must not be installed during this process.
- Tighten the new bolt - 3 - for the camshaft adjusters - 2 and 4 - to 60 Nm + 90° (1/4) additional turn.
- Apply sealant (D 176 501) onto the clean sealing surfaces of the sealing flange as shown.
• Note the alignment pins in cylinder block.
- Install the sealing flange immediately.
- To do this, insert all the bolts by hand and tighten them to 10 Nm.
- Install the crankshaft seal in the sealing flange. Refer to => [ Crankshaft Oil Seal, Flywheel Side ] Service and Repair.
- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.
If the seal in the timing chain cover is to be replaced, refer to => [ Timing Chain Cover Seal, Installing ] Timing Chain Cover Assembly Overview
- Install sealant (D 176 501) to the sealing surface of the timing chain cover facing the cylinder head.
- Prepare the cylinder head gasket for installation, refer to => [ Cylinder Head Gasket, Preparing for Assembly ] Cylinder Head.
- Lubricate the oil channel seal O-ring and insert it in the timing chain cover.
- Install the timing chain cover, insert all bolts and lightly tighten.
- First tighten the M8 bolts, - item 8 - in the => [ Timing Chain Cover Assembly Overview ] Timing Chain Cover Assembly Overview to 23 Nm, then tighten the M6 bolts, - item 2 - in the => [ Timing Chain Cover Assembly Overview ] Timing Chain Cover Assembly Overview to 8 Nm.
- Install the camshaft roller chain tensioner and tighten it to 40 Nm.
- Rotate the crankshaft twice in direction of engine rotation and check the valve timing again.
- Install the cylinder head cover and intake manifold. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.