Valve: Adjustments

Valve Timing, Adjusting

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Locking Pin (T03006)

• Multipoint Socket (T10035)

• Counterhold Tool (T10172)

• Camshaft Clamp (T40070)

• 2 M8 x 16 Bolts

Modifying the Counterhold Tool (T10172) :






- Remove the adapter (T10172/1) and install the 2 M8 x 16 bolts - A -.

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

• The valve timing must be adjusted if the camshaft sprockets were loosened during repairs or if the valve timing is not set.

Securing the camshafts if the valve timing is correct:

- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Service and Repair.

- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

- Lock the crankshaft in place to adjust the valve timing. Refer to => [ to Check/Adjust Valve Timing ] Procedures.

- Install the camshaft clamp (T40070) to the camshafts as illustrated and tighten the bolts to 20 Nm.






If the bolts could not be installed easily, attempt to rotate the exhaust camshaft on the recess, using an open end wrench - A - (18 or 19 mm, depending on the wrench width) slightly in the - direction of the arrow - in order to eliminate any play in the chain.

- Relieve the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the chain tensioner piston and tensioning rail and press in the - direction of the arrow -.






- Secure the fully pushed in piston using the locking pin (T03006). The pin must be inserted until it stops.

Securing the camshafts if the valve timing is not correct:

- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] Service and Repair.

- Rotate the crankshaft to cylinder 5 Top Dead Center (TDC). Refer to => [ to Check/Adjust Valve Timing ] Procedures but do not lock the crankshaft with the locking pin (T40069).

- Rotate the crankshaft so the camshaft clamp (T40070) can be easily installed onto the camshafts, as illustrated.






- Tighten the camshaft clamp (T40070) bolts to 20 Nm.

Removing the sprockets:

- Release the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the chain tensioner piston and tensioning trail and press in the - direction of the arrow -.






- Secure the fully pushed in piston using a locking pin (T03006). The pin must be inserted until it stops.

- Remove the bolts - 1 and 4 - using the multipoint socket (T10035) and then remove the sprockets - 2 and 3 -.

If necessary, the sprocket - 3 - must be pried off lightly using a screwdriver.

• Lock the crankshaft, refer to => [ Crankshaft, Locking ] Procedures in case it still not secured. The crankshaft must only be rotated slightly around the TDC point for this. Otherwise there is a risk the valves rest on the pistons.

Adjusting the timing:

• The crankshaft is secured using the locking pin (T40069)

• The camshafts are secured using the camshaft clamp (T40070)

• The chain tensioner is tensioned

- Place the sprockets - 2 and 3 - in the timing chain as illustrated and then mount them on the camshafts. Install the new bolts - 1 and 4 - hand tight.






The sprockets must still be able to be rotated, however they must not tilt.

• Make sure that timing chain lies correctly in the guide and tensioning rails.

- Push the piston in and pull the locking pin (T03006) out in order to release the tension on the chain tensioner.

- Install the counterhold tool (T10172) to the exhaust camshaft sprocket - 4 -.






• A second mechanic is required for the following steps.

- Push the counterhold tool (T10172) in the - direction of the arrow - in order to tension the timing chain.

- Tighten the intake camshaft sprocket bolt - 2 - first, then the exhaust camshaft sprocket bolt - 3 - to 60 Nm.

Then, tighten the bolts - 2 and 3 - and additional 90° (1/4) turn.

• When applying the additional torque of 90°, the timing chain must no longer be held at preload.

- Remove the camshaft clamp (T40070).






- Remove the locking pin (T40069) - 1 - from the cylinder block.






- Rotate the crankshaft 2 revolutions in engine rotation direction and lock it in place, refer to => [ to Check/Adjust Valve Timing ] Procedures.

- Check the valve timing. Refer to => [ Valve Timing, Checking ] Adjustments.

If the valve timing is not correct:

- Loosen the camshaft sprocket bolts again and adjust the valve timing again (replace the camshaft bolts).

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

• Remove the locking pin (T40069) from the cylinder block and install the plug.

• Fill the coolant. Refer to => [ Draining and Filling ] Procedures.