Valve Timing, Adjusting
Valve Timing, Adjusting
Special tools, testers and auxiliary items required
^ Camshaft bar T10068 A
^ Counter-holder tool T10069
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Sealant D 176 501
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.
^ To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
Note:
^ The following procedure is only possible with engine removed and is only described that way. 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 plate for intermediate shaft drive:
- Adjust position of crankshaft relative to intermediate shaft. The milled tooth on the drive chain sprocket - B - must align with the main bearing joint (TDC cyl. 1).
- Install both bolts without the guide rail collar - 2 - and tighten to 10 Nm.
Note:
^ Note direction of rotation of used chains.
- Install guide rail - 2 - with roller chain - 1 - and both chain sprockets - 3 - and - 4 -.
^ Roller chain marking on chain sprocket - 4 - must align with notch - C - or - D -.
During installation make sure that the roller chain runs completely straight in the guide rail from the crankshaft to the intermediate shaft.
- Tighten chain sprockets - 3 - and - 4 - on the intermediate shaft by hand.
Note:
^ Be aware 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 rail pressed against chain tensioner.
- Install the chain tensioner in this position and tighten it to 8 Nm.
- Lock vibration damper using counter-holder tool T10069.
- Tighten the new mounting 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 counter-holder 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 the camshafts in cylinder head to TDC No. 1 cylinder.
Note:
^ If necessary use 32 mm open end wrench to turn camshafts - arrow - to the correct position. Camshaft bar T10068 A must not be inserted during this process.
- The camshaft bar T10068 A must engage in both shaft grooves.
Note:
^ If the cylinder head is removed, install it.
- Place camshaft roller chain on intermediate shaft chain sprocket.
- Route chain between tensioning rail and guide rail toward control housing.
Note:
^ The camshaft bar T10068 A remains installed.
^ Both camshaft adjusters (identification: "24E" on intake side and "32A" on exhaust side) can only bolted 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 - direction of arrow - until it stops 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.
Note:
^ 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.
- Arrow - 1 - on camshaft adjuster "24E" must align with notch - 2 - of control housing.
- Now count exactly 16 rollers on timing chain to the 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" positioned in this way 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.
- Exhaust camshaft adjuster must be able to be inserted easily on exhaust camshaft and be tightened hand-tight.
- Check position of both camshaft adjusters in positions - A and B - with the 16 rollers between - 1 and 2 - again for the correct adjustment.
- Remove camshaft bar T10068 A.
- Turn over crankshaft twice in direction of engine rotation and check valve timing.
Note:
^ When turning 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 fastening camshaft tightly with an open-end wrench 32 mm - arrow -.
Note:
^ Camshaft bar T10068 A must not be inserted during this process.
- Tighten the new mounting bolts - 3 - for the intake and exhaust camshaft adjusters - 4 - and - 2 - to 60 Nm + 90° (1/4 turn).
- 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 the mounting bolts by hand and tighten them 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.
- Prepare cylinder head gasket for installation.
- Lubricate oil channel seal O-ring and insert in timing chain cover.
- Install timing chain cover, insert all fastening bolts and lightly tighten.
- First tighten the M8 bolts to 23 Nm, then tighten the M6 bolts to 8 Nm.
- Install the camshaft roller chain tensioner and tighten it to 40 Nm.
- Turn over crankshaft twice in direction of engine rotation and check valve timing again.
- Install cylinder head cover and intake manifold.