Camshaft Adjuster With Timing Chain, Installing
Camshaft Adjuster with Timing Chain, Installing
• A revised camshaft adjuster is being installed as of 12.08. To recognize this, the exhaust camshaft adjuster 32A has a plastic cover.
=> [ Vehicles through 11.08 ]
=> [ Vehicles from 12.08 ]
Vehicles through 11.08
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counter-Holder Tool (T10069)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Adjustment Tool (T10332) (Without a mechanical vacuum pump)
• Adjustment tool (T10363) (With a mechanical vacuum pump)
• Sealant (D 176 501 A1)
- Rotate the crankshaft, using the vibration damper bolt, in engine rotation direction to the Top Dead Center (TDC) mark - arrow - for cylinder 1.
- Position the camshafts in the cylinder head to the TDC for cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Install the (T10068 A) into both camshaft grooves. If necessary, slightly rotate the camshaft back and forth using an open end wrench.
Without a Mechanical Vacuum Pump
- Secure the position of the high pressure pump diver pinion using (T10332).
With a Mechanical Vacuum Pump
- Secure the position of the high pressure pump diver pinion using adjustment tool (T10363). The mark - A - on the high pressure pump sprocket must be at the top.
Continuation for All
Install the camshaft adjuster for the intake camshaft as follows:
• The camshaft adjusters can be attached to the camshaft in only one position - arrows -. This is due to the alignment pin.
- Check the crankshaft to ensure it is on the TDC mark.
- Turn the sensor wheel - 1 - all the way to the right on the intake camshaft adjuster, which was previously removed. Holder the adjuster in this position.
• 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 timing chain must be routed.
- Place the intake camshaft adjuster with the timing chain in place on the camshaft. Note the following:
• The timing chain for the high pressure pump drive train sprocket must not hang through.
• It must be easy to mount the camshaft adjuster with the timing chain taut and the bolt can then be tighten by hand.
• Arrow - 1 - on the camshaft adjuster 24E must align with the right notch - 2 - of the control housing. For the mark on the control housing, refer to => [ Control Housing Marks ] Testing and Inspection.
- Count exactly 16 rollers on the timing 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 position. Therefore the sensor wheel cannot be rotated when adjusting the valve timing. If the locking mechanism is in its rest position, it is not engaged (locked), then 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 into the camshaft timing chain. The previously counted 16 rollers must lie between the arrow marks 24E and 32A.
- Place the camshaft adjuster 32A with the camshaft timing chain installed on the exhaust camshaft. Note the following:
• The mark - 1 - on the camshaft adjuster which the "arrow" points to must align with the notch - 2 - at the far right on the control housing. For the marks on the control housing, refer to => [ Control Housing Marks ] Testing and Inspection.
• The exhaust camshaft adjuster must be able to be installed easily on the exhaust camshaft and the bolt be tightened hand tight.
• A small offset between the mark - 1 - and the notch - 2 - is permitted.
- Remove the (T10332) or (T10363) from the bearing shaft.
- Remove the (T10068 A).
- Install the camshaft timing chain tensioner and tighten it to 50 Nm.
- Rotate the crankshaft 2 revolutions in engine rotation direction and check the valve timing. Refer to => [ Valve Timing, Checking ] Testing and Inspection.
If the mark match:
- Secure the respective camshaft to be tightened using a 27 mm open end wrench on the recess - arrow -.
• The (T10068 A) must not be installed during this process.
• Be aware that all sprocket bolts must be replaced.
- Tighten the new bolts for the intake and exhaust camshaft adjusters to 60 Nm + 90° (1/4) additional turn.
Install the sealing flange. Refer to => [ Sealing Flange, Transmission Side ] Service and Repair.
Vehicles from 12.08
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counter-Holder Tool (T10069)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Adjustment Tool (T10332) (Without a mechanical vacuum pump)
• Adjustment Tool (T10363) (With a mechanical vacuum pump)
• Sealant (D 176 501 A1)
- Rotate the crankshaft in engine rotation direction to Top Dead Center (TDC) for cylinder 1.
- Position the camshafts in the cylinder head to TDC for cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Install the (T10068 A) into both camshaft grooves. If necessary, slightly rotate the camshaft back and forth using an open end wrench.
- Secure the position of the high pressure pump diver pinion using (T10363). The mark - A - on the on high pressure pump sprocket must be at the top.
Install the Camshaft Adjuster for the Intake Camshaft as Follows:
• The camshaft adjusters can be attached to the camshaft mount in only one position - arrows -. This is due to the alignment pin.
- Place the intake camshaft adjuster with the timing chain in place on the camshaft. Note the following:
• The timing chain for the high pressure pump sprocket must not hang through.
• It must be easy to mount the camshaft adjuster with the timing chain taut and the bolt can then be tighten by hand.
• The arrow - 1 - on the camshaft adjuster 24E must align with the right notch - 2 - of the control housing. For marks on the control housing, refer to => [ Control Housing Marks ] Testing and Inspection.
- Count exactly 16 rollers on the timing chain to the right from the tooth with the arrow - 1 - aligning with the notch - 2 -. Mark this roller with a colored mark.
• The camshaft adjuster is locked in the rest position. Therefore the sensor wheel cannot be rotated when adjusting the valve timing. If the locking mechanism is in its rest position, it is not engaged (locked), then 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 into the camshaft timing chain. The previously counted 16 rollers must lie between the arrow marks 24E and 32A.
- Place the camshaft adjuster 32A with the camshaft timing chain installed on the exhaust camshaft. Note the following:
• The arrow - 1 - on the camshaft adjuster 32A must align with the notch - 2 - on the right side of the control housing. For marks on the control housing, refer to => [ Control Housing Marks ] Testing and Inspection.
• The exhaust camshaft adjuster must be able to be installed easily onto the exhaust camshaft and the bolt be tightened hand tight.
• A slight offset between the 32A mark and the notch is permitted.
- Remove the (T10363) out of the bearing shaft.
- Remove the (T10068 A).
- Install the timing chain tensioner and tighten it to 50 Nm.
- Rotate the crankshaft 2 revolutions in the engine rotation direction and check the valve timing.
If the mark match:
- Secure the respective camshaft to be tightened using a 27 mm open end wrench on the recess - arrow -.
• The (T10068 A) must not be installed during this process.
• Be aware that all sprocket bolts must be replaced.
- Tighten the new bolts for the intake and exhaust camshaft adjuster to 60 Nm + 90° (1/4) additional turn.
Install the sealing flange. Refer to => [ Sealing Flange, Transmission Side ] Service and Repair.