Camshaft Adjuster with Timing Chain, Installing
Camshaft Adjuster with Timing Chain, Installing
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counter-Hold Tool (T10172)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Adjustment Tool (T10363)
• Sealant (D 176 501 A1)
Removing
- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.
- Disconnect the following connectors:
1 - Camshaft position sensor
2 - Camshaft adjustment valve 1
3 - Camshaft position sensor 2
4 - Exhaust camshaft adjustment valve 1
- Remove the mechanical vacuum pump. Refer to => [ Mechanical Vacuum Pump ] Mechanical Vacuum Pump.
- Remove the coolant pipe from the cover.
- Remove the cover bolts - arrows - and pry off the cover.
- Remove the noise insulation.
- Rotate the crankshaft from below, using the counter-holder tool (T10172) in engine rotation direction to the Top Dead Center (TDC) mark for cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Loosen the exhaust side camshaft adjuster bolt approximately 1 turn while counter-holding the camshaft on the recess using a 27 mm open end wrench.
- Loosen the intake side camshaft adjuster bolt approximately 1 turn while counter-holding the camshaft on the recess using a 27 mm open end wrench.
- Install the camshaft bar (T10068 A) into both camshaft grooves. If necessary, slightly rotate the camshafts back and forth using the open end wrench.
- Secure the high pressure pump drive sprocket position using the adjustment tool (T10363). The mark - A - on the high pressure pump drive sprocket must be at the top.
• If the vacuum pump drive pins are not vertical: Remove the camshaft bar (T10068 A). Rotate the crankshaft in engine rotation direction until the pins are vertical and the camshaft bar (T10068 A) can be installed.
- Remove the timing chain tensioner - arrow -.
- Label the chain links opposite the marks on the camshaft adjusters. The labeling of the timing chain simplifies installation.
- Completely remove the camshaft adjuster bolts and remove the camshaft adjusters.
• The timing chain is held on the oil pump chain sprocket by the lower timing chain cover. The timing chain cannot skip.
Installing
Conditions
• Crankshaft is at TDC
• The high pressure pump drive sprocket is secured with the adjustment tool (T10363).
• The camshafts are secured with the camshaft bar (T10068 A).
First, install the intake camshaft adjuster as follows:
• The camshaft adjusters are locked in their "rest position". Therefore the sensor wheel cannot be rotated when adjusting the valve timing. If the locking mechanism in its rest state is not engaged (locked) rotate the adjuster in both directions by hand until it locks. If that is not possible, replaced the camshaft adjuster.
• The camshaft adjuster can be attached to the camshaft in only one position. This is due to the alignment pin - arrows -.
- 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 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 - on the control housing. For the marks on the control housing, refer to => [ Marks on the Control Housing with FSI Engines ] Adjustments.
- Tighten the camshaft adjuster bolt by hand.
- Count exactly 16 timing chain rollers to the right, from the tooth with arrow - 1 - aligning with the notch - 2 -. Mark this roller with a colored mark.
- Install the exhaust camshaft adjuster "32A" into the camshaft timing chain. The previously counted 16 rollers must lie between the arrows "24E" and "32A".
- Place 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 the marks on the control housing, refer to => [ Marks on the Control Housing with FSI Engines ] Adjustments.
• The exhaust camshaft adjuster must be able to be inserted easily on the exhaust camshaft. If necessary, move the camshaft back and forth slightly.
- Remove the adjustment tool (T10363).
- Remove the camshaft bar (T10068 A).
- Install the timing chain tensioner - arrow -. Tightening specification: 50 Nm.
- Rotate the crankshaft 2 revolutions in engine rotation direction and check the valve timing. Refer to => [ Valve Timing, Checking ] Adjustments.
If the marks match:
- Secure the respective camshaft to be tightened using a 27 mm open end wrench on the recess - arrow -.
• The camshaft bar (T10068 A) must not be installed during this process.
• Be aware that all chain sprocket bolts must be replaced.
- Tighten the new bolts for the intake and exhaust camshaft adjusters to 60 Nm + an additional 90° (1/4) turn.
- Clean the sealing surfaces on the cover. Coat the sealing surface with silicone adhesive sealant (D 176 501 A1).
- Install the cover and tighten the bolts - arrows - diagonally to 8 Nm.
Further installation is performed in the reverse order of removal.