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Valve Timing, Installing and Adjusting




Valve timing, adjusting

Special tools and equipment
- T10068 Camshaft bar
- T10069 Counter support
- VAG 1331 Torque wrench (5-50 Nm)
- VAG 1332 Torque wrench (40-200 Nm)
- AMV 174 004 01 Sealing compound
- AMV 188 001 01 Sealing compound

Work sequence

CAUTION:
When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
- Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.

Note: The following work sequence is described for an engine after removal. Start with the adjustments at the relevant position depending on how far the engine has been disassembled

Install roller chain and chain tensioner with tensioning track for intermediate shaft drive:





- Adjust position of crankshaft relative to intermediate shaft:
Milled tooth of drive pinion -B- to match with bearing separating gap (TDC Cyl. 1)

- Install both bolts without collar for glide track -2- and tighten to 10 Nm.

Note: Observe direction of rotation marks of used roller chain, Refer to Engine, disassembling and assembling, See Fig 1

- Install glide track -2- with roller chain -1- and both chain sprockets -3- and -4-. Marking on sprocket -4- for roller chain must match with notch -C- or -D- on thrust washer of intermediate shaft.

- When installing, make sure that the roller chain runs completely straight in glide track from crankshaft to intermediate shaft.





- Bolt chain sprockets -3- and -4- on the intermediate shaft by hand.

Note: Note that all securing bolts for chain sprockets must be replaced.

- Install chain tensioner on opposite side.
- To do so, use a small screwdriver to release tension of locking splines in chain tensioner and press tensioning track against chain tensioner.
- Install chain tensioner in this position and tighten to 8 Nm.





- Secure harmonic balancer using retainer -T10069- or -3406-.





- Remove chain sprockets -3- and -4- for intermediate shaft and tighten to 60 Nm plus additional 1/4 turn (90°).
- Check position of crankshaft -B- to intermediate shaft -C- or -D- once again.
- Turn engine to TDC cyl. 1 position again.
- Adjust installed camshafts in cylinder head to TDC cyl. 1





Note: If necessary, turn camshafts at position indicated by -arrow- using spanner wrench 32 mm to achieve alignment. The camshaft ruler T10068 must not be inserted during this process.





- It must be possible to insert camshaft bar T10068 into both shaft slots.

Note: If the cylinder head is removed, Refer to Cylinder Head, Service and Repair, Cylinder Head, Removing and Installing

- Place camshaft roller chain on intermediate shaft chain sprocket.
- Guide chain between tensioning track and glide track in direction of control housing.

Note: First install intake camshaft timing adjuster along with fitted camshaft roller chain.





- Position both camshaft timing adjusters (identification: 24E on inlet side and 32A on exhaust side) on the camshaft mountings -arrows-.






Note: The exhaust camshaft timing adjuster -1- can be turned in two directions. When installing, ensure that the sensor wheel -2- for the CMP sensor -G163- is turned onto limit stop in direction of -arrow-. Distance between both milled teeth between intake and exhaust camshaft adjusters is exactly 16 rollers on camshaft roller chain






- Install exhaust camshaft timing adjuster with fitted camshaft roller chain.

Marks -A and B- on camshaft timing adjusters must align with notches -arrows- on control housing -C-.
Milled tooth -1- or -2- from camshaft adjuster also points to notch of control housing -C-.

- Tighten new securing bolts for camshaft adjusters by hand.

Note: Distance between both milled teeth between intake and exhaust camshaft adjusters is exactly 16 rollers on camshaft roller chain

- Remove camshaft ruler -T10068-.
- Turn crankshaft two full turns in engine direction of rotation and check valve timing.

Note: When rotating crankshaft, instead of the chain tensioner, the tensioning track must be pressed against the camshaft roller chain by hand.

If valve timing is not OK:
- Repeat timing adjustment.

If the valve timing is OK:





Note: Hold camshaft to be tightened at position indicated by -arrow- using a spanner wrench (32 mm). Camshaft ruler -T10068- must not be fitted when doing this.





- Install new mounting bolts -3- of intake and exhaust camshaft adjuster -4- and -2- and tighten to 60 Nm plus additional 1/4 turn (90°).
- Coat sealing surface of sealing flange with Sealant -AMV 188 001 02- and install. Tighten securing bolt to 8 Nm.
- Replace sealing ring for sealing flange.
- Prepare cylinder head gasket for installation
- Coat sealing surface of cover piece with Sealant -AMV 188 001 02-
- Oil O-ring for oil channel sealing and insert sealing ring into cover piece.
- Install cover piece, insert all securing bolts and lightly tighten.
- Also tighten securing bolts M8 to 25 Nm and then install securing bolts M6 and tighten to 8 Nm.
- Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
- Turn crankshaft twice in direction of engine rotation and check valve timing once again.
- Check camshaft adjustment

Caution Observe the following for all installations, especially in engine compartment due to lack of room:
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.
Watch for sufficient clearance to all moving or hot components.
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