Camshaft Adjuster With Camshaft Drive Timing Chain, Installing

Camshaft Adjuster with Camshaft Drive Timing Chain, Installing

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
^ Adjustment tool T10332 (for vehicles without mechanical vacuum pump)
^ Adjustment tool T10363 (for vehicles with mechanical vacuum pump)
^ Sealant D 176 501 A1





- Turn the crankshaft using the vibration damper bolt in the direction of engine rotation until the engine is positioned at TDC - arrow for cylinder 1.
- Position the camshafts in cylinder head to TDC No. 1 cylinder. 1.





Cam lobes - A - of cylinder 1 must face each other.





- Insert the camshaft bar T10068 A into both shaft grooves. If necessary, slightly turn the camshaft back and forth using an open-end wrench.





Without Mechanical Vacuum Pump
- Secure the position of the drive pinion for the high pressure pump using the adjustment tool T10332





With Mechanical Vacuum Pump
- Secure the position of the drive pinion for the high pressure pump using the adjustment tool T10363. Marking - A - on high pressure drive camps must be at top.

Continuation for All

First Install Camshaft Adjuster for Intake Camshaft as Follows





Note:
^ Both camshaft adjusters (identification: "24E" on intake side and "32A" on exhaust side) can only be bolted in one position on the camshaft arrows - by an alignment pin.





- Verify crankshaft TDC position.





- Turn the sensor wheel - 1 - on the intake camshaft adjuster clockwise - in direction of arrow - until it stops and hold the adjuster in this position.

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 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 can then be tighten by hand.





^ Arrow - 1 - on camshaft adjuster "24E" must align with the right 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 with the tooth at arrow marking into camshaft timing chain so that the exact, previously counted 16 rollers lie between markings "24E" and "32A".
- Place camshaft adjuster "32A" with camshaft timing chain installed on exhaust camshaft. Note the following:





^ Marking - 1 - on camshaft adjuster which the "arrow" points to must align with notch - 2 - at far right on control housing.
^ Exhaust camshaft adjuster must be able to be inserted easily on exhaust camshaft and be tightened hand-tight.

Note:
^ A small offset between the marking - 1 - and notch - 2 - is permitted.

- Remove adjustment tool T10332 or adjustment tool T10363 from bearing shaft.
- Remove camshaft bar T10068 A.
- Install chain tensioner for the timing chain and tighten to 40 Nm.
- Rotate the crankshaft 2 revolutions in direction of engine rotation and check the valve timing.

If the markings match:





- Secure the respective camshaft to be tightened using an open end wrench (27 mm) - arrow -.

Note:
^ Camshaft bar T10068 A must not be inserted during this process.
^ Be aware that all chain sprocket securing screws/bolts must be replaced.

- Tighten the new bolts for the intake and exhaust camshaft adjuster to 60 Nm + 90 degree (1/4 turn).

Now install sealing flange as follows.