Camshaft Adjuster with Timing Chain, Installing
Camshaft Adjuster with Timing Chain, Installing
• A revised camshaft adjuster is being installed as of 12.08. To recognize the camshaft adjuster: Starting in 12.08 the exhaust camshaft adjuster 32A has a plastic cover. For the allocation, refer to the parts catalog.
• Procedure is only possible when engine is removed from the engine compartment!
=> [ Vehicles through 11.08 ]
=> [ Vehicles from 12.08 ]
Vehicles through 11.08
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counter-Holder Tool (T10069)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (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)
- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.
- Position the camshafts in cylinder head to Top Dead Center (TDC) cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Install the (T10068 A) into both camshaft grooves. If necessary, rotate the camshaft back and forth slightly using an open end wrench on the camshaft recesses.
Without a Mechanical Vacuum Pump
- Secure the position of the high pressure pump drive pinion using the (T10332).
With a Mechanical Vacuum Pump
- Secure the position of the high pressure pump drive pinion using (T10363). The mark - A - on the high pressure drive pinion must be at the top.
Continuation for All
First, install the camshaft adjuster for the intake camshaft as follows:
• The camshaft adjusters can be attached to the camshaft in only one position. This is due to the alignment pin - arrows -.
- Check the crankshaft TDC position.
- Turn the wheel - 1 - all the way to the right on the adjuster, which was previously removed. 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 sprocket and then the camshaft timing chain must be routed.
- Place the intake camshaft adjuster with the timing chain in place onto the camshaft. Note the following:
• The timing chain for the high pressure pump drive pinion must not hang through.
• It must be easy to install the camshaft adjuster with the timing chain taut so the bolt can then be tighten by hand.
• The arrow - 1 - on the camshaft adjuster 24E must align with the right notch - 2 - of the control housing. Marks on control housing, refer to => [ Marks on Control Housing ] Adjustments.
- Count exactly 16 rollers on the timing chain to the right from tooth with the arrow - 1 - aligning with notch - 2 -. Mark this roller with a colored mark.
• The Exhaust camshaft adjuster is locked in the rest position. Therefore the 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 the camshaft adjuster.
- Install the exhaust camshaft adjuster 32A into the timing chain. The previously counted 16 rollers must lie between the arrow marks 24E and 32A.
- Place the camshaft adjuster 32A with the timing chain installed on the exhaust camshaft. Note the following:
• The mark - 1 - on the camshaft adjuster which the arrow points to must align with the notch - 2 - at the far right on the control housing. Marks on the control housing. Refer to => [ Marks on Control Housing ] Adjustments.
• Exhaust camshaft adjuster must be able to be installed easily onto the exhaust camshaft and the bolt be tightened by hand.
• A small offset between the mark - 1 - and notch - 2 - is permitted.
- Remove the (T10332) or the (T10363) from the bearing shaft.
- Remove the (T10068 A).
- Install the chain tensioner and tighten it to 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 camshaft recess - arrow -.
• The (T10068 A) must not be installed during this process.
• Be aware that all sprocket bolts must be replaced.
- Tighten the new bolts for the intake and exhaust camshaft adjusters to 60 Nm + 90° (1/4) additional turn.
Install the sealing flange. Refer to => [ Sealing Flange, Transmission Side ] Service and Repair.
Further installation is performed in reverse order.
Vehicles from 12.08
Special tools, testers and auxiliary items required
• Camshaft Bar (T10068 A)
• Counter-Holder Tool (T10069)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Adjustment Tool (T10332) (without mechanical vacuum pump)
• Adjustment Tool (T10363) (with mechanical vacuum pump)
• Sealant (D 176 501 A1)
- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.
- Position the camshafts in the cylinder head to Top Dead Center (TDC) cylinder 1.
The camshaft lobes - A - for cylinder 1 must face each other.
- Install the (T10068 A) into both camshaft grooves. If necessary, rotate the camshaft back and forth slightly using an open end wrench on the camshaft recesses.
- Secure the position of the high pressure pump drive pinion using the (T10363). The mark - A - on the high pressure drive pinion must be at the top.
First, install the camshaft adjuster for the intake camshaft as follows:
• The camshaft adjusters can be attached to the camshafts 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 pinion must not hang through.
• It must be easy to install the camshaft adjuster with the timing chain taut so the bolt can then be tighten by hand.
• The arrow - 1 - on camshaft adjuster 24E must align with the right notch - 2 - of the control housing. Marks on control housing, refer to => [ Marks on Control Housing ] Adjustments.
- Count exactly 16 rollers to the right on the timing chain from the tooth with the arrow - 1 - aligning with the notch - 2 -. Mark this roller with a colored mark.
• The camshaft adjusters are locked in their rest position. Therefore the 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 the camshaft adjuster.
- Install the exhaust camshaft adjuster 32A into the timing chain. The previously counted 16 rollers must lie between the arrow marks 24E and 32A.
- Place the camshaft adjuster 32A with the timing chain installed to 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. Marks on control housing. Refer to => [ Marks on Control Housing ] Adjustments.
• The exhaust camshaft adjuster must be able to be installed easily on the exhaust camshaft and the bolt be tightened by hand.
• A slight offset between the 32A mark and the notch is permitted.
- Remove the (T10363) out of bearing shaft.
- Remove the (T10068 A).
- Install the chain tensioner and tighten it to 50 Nm.
- Rotate the crankshaft 2 revolutions in engine rotation direction and check the valve timing.
If the marks match:
- Secure the respective camshaft to be tightened using a 27 mm open end wrench on the camshaft recess - arrow -.
• The (T10068 A) must not be installed during this process.
• Be aware that all sprocket bolts must be replaced.
- Tighten the new bolts for the intake and exhaust camshaft adjusters to 60 Nm + 90° (1/4) additional turn.
Install the sealing flange. Refer to => [ Sealing Flange, Transmission Side ] Service and Repair.
Further installation is performed in reverse order.