Camshaft Adjuster
Camshaft Adjuster
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counterhold Tool (T10172)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Adjustment Tool (T10363)
• Silicone Adhesive 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 (CMP) sensor
2 - Camshaft adjustment valve 1
3 - CMP sensor 2
4 - Exhaust camshaft adjustment valve 1
- Remove the vacuum pump. Refer to => [ Vacuum Pump ] Vacuum Pump.
- Remove the coolant pipe from the cover.
- Remove the cover bolts - arrows - and the cover.
- Remove the noise insulation.
- Rotate the crankshaft from below, using the counterhold tool (T10172) in the 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 camshaft adjuster bolt on the exhaust side approximately 1 turn. Counter hold the camshaft using a open end wrench on the recess while doing this.
- Loosen the camshaft adjuster bolt on the intake side approximately 1 turn. Counter hold the camshaft using an open end wrench on the camshaft recess while doing this.
- Install the camshaft bar (T10068 A) into both camshaft grooves. If necessary, slightly turn the camshaft back and forth using the open end wrench.
- Secure the high pressure pump sprocket position using the adjustment tool (T10363). The mark - A - on the high pressure pump sprocket must be at the top.
• If the vacuum pump drive pins are not vertical: Remove the camshaft bar (T10068 A). Rotate the crankshaft further until the lug is perpendicular and it is possible to insert the camshaft bar (T10068 A).
- 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 unscrew the camshaft adjuster bolts and remove the camshaft adjusters.
• The timing chain is held by the sealing flange on the oil pump chain sprocket. The timing chain cannot skip.
Installing
Conditions:
• The crankshaft is at TDC
• The high pressure pump sprocket is secured using the adjustment tool (T10363)
• The camshafts are secured using the camshaft bar (T10068 A)
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 position is not engaged (locked) turn the adjuster in both directions by hand until it locks. If that is not possible, replaced camshaft adjuster.
• The camshaft adjusters can be attached to the camshaft in only one position. This is due to the alignment pins - arrows -.
- Install the intake camshaft adjuster, with the timing chain on, onto the camshaft. Watch for 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 be installed hand tight.
• 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 hand tight.
- Starting with the tooth, that lines up with the arrow - 1 - and the notch - 2 -, count exactly 16 rollers on the timing chain. Mark this roller with a colored marker.
- Insert the exhaust camshaft adjuster "32A" into the camshaft timing chain. The previously counted 16 rollers must lie between the arrow marks for 24E and 32A.
- Place the camshaft adjuster "32A" with the camshaft timing chain installed onto the exhaust camshaft. Watch for 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 installed easily onto the exhaust camshaft. If necessary, move the camshaft slightly back and forth.
- Remove the adjustment tool (T10363) from the drive shaft.
- 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.
If the marks match:
- Hold the camshaft that is going to be tightened using a 27 mm open end wrench on the camshaft recesses - arrows -.
• The camshaft bar (T10068 A) must not be installed during this process.
• Note that all the bolts for the sprockets 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 rear cover. Coat the sealing surface with silicone adhesive sealant (D 176 501 A1).
- Install the cover and tighten the bolts - arrows - to 8 Nm diagonally.
Further installation is performed in the reverse order of removal.