Camshaft Adjuster with Camshaft Drive Timing Chain, Installing
Camshaft Adjuster with Camshaft Drive Timing Chain, Installing
• Work sequence only possible when engine is removed from engine compartment!
Special tools, testers and auxiliary items required
• Camshaft bar (T10068 A)
• Counter-holder tool (T10069)
• Torque wrench (VAG 1331)
• Torque wrench (VAG 1332)
• Adjustment tool (T10332) (for vehicles without mechanical vacuum pump)
• Adjustment tool (T10363) (for vehicles with mechanical vacuum pump)
• Sealant (D 176 501 A1)
- Adjust the crankshaft at the vibration damper bolt in the direction of engine rotation to the Top Dead Center (TDC) cylinder 1 marking - arrow -.
- Position the camshafts in cylinder head to TDC No. 1 cylinder. 1.
Cams - A - of cylinder 1 must face each other.
- Insert thecamshaft 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). The marking - A - on the on high pressure drive cams must be at the top.
Continuation for All
First install camshaft adjuster for intake camshaft as follows
• Both camshaft adjusters (identification: "24E" on intake side and "32A" on exhaust side) can only bolted in one position on the camshafts - arrows - by an alignment pin.
- 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.
• 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. Markings on control housing, refer to --> [ Markings on Control Housing ] Testing and Inspection
- 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.
• 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. Markings on control housing, refer to --> [ Markings on Control Housing ] Testing and Inspection
• Exhaust camshaft adjuster must be able to be inserted easily on exhaust camshaft and be tightened hand-tight.
• 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, refer to --> [ Valve Timing, Checking ] Testing and Inspection.
If the markings match:
- Secure the respective camshaft to be tightened using an open end wrench (27 mm) - arrow -.
• 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° (1/4 turn). (90°).
- Install the upper cover for the timing chain, tightening specifications. Refer to --> [ Timing Chain Cover and Side Sealing Flange Assembly Overview ] Timing Chain Cover and Side Sealing Flange Assembly Overview.