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 Touareg V10 (T10172)
• Camshaft Clamp (T40070)
• Crankshaft Adapter (T03003)
• Locking Pin (T40069)
• Two M8 x 16 Bolts
Modifying the Counterhold Tool Touareg V10 (T10172) :
- Remove the adapters (T10172/1) and install the two 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 noise insulation.
- Remove the rear section of the front wheel housing liner..
- Install the crankshaft adapter (T03003) onto the vibration damper bolts.
The crankshaft adapter (T03003) can only be installed correctly in one position.
- Rotate the crankshaft in engine rotation direction - arrow - far enough until the arrow - A - on the crankshaft adapter (T03003) points downward vertically, relative to the engine axis.
This position corresponds approximately to the Top Dead Center (TDC) position of the crankshaft at cylinder 5.
• With the engine removed, the TDC mark can also be seen on the vibration damper and sealing flange. The notches - A and B - must align.
- Remove the plug - 1 - from the cylinder block.
- Look through the threaded hole. Make sure the hole - 2 - in the crankshaft is lined up wit the threaded hole.
Use a mirror for this.
- Rotate the crankshaft slightly, if necessary.
- When the holes line up, install the locking pin (T40069) all the way into the threaded hole and tighten it to 10 Nm.
• With the engine removed, the TDC mark can also be seen on the vibration damper and sealing flange. The notches - A and B - must align.
- Make sure the crankshaft cannot be rotated.
- 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.
• If the threaded holes - arrows - in the camshafts do not point upward, the crankshaft must be rotated one rotation (360°) in engine rotation direction.
In order to be able to precisely check and adjust the valve timing, always note the following:
• Rotate the crankshaft only in engine rotation direction - arrow -. Do not rotate the crankshaft back, not even slightly!
• The crankshaft must not be rotated past the TDC mark. This means the hole - 2 - in the crankshaft must not be above the threaded opening.
If the crankshaft was rotated past the TDC mark:
- Rotate the crankshaft back 45° opposite the engine rotation direction.
- Rotate the crankshaft again in engine rotation direction to TDC
When the crankshaft is positioned slightly in front of the TDC position (hole in the crankshaft is 90% visible), the locking pin (T40069) can be installed, although slightly more difficult.
- Install the camshaft clamp (T40070) to the camshafts as illustrated and tighten the bolts to 20 Nm.
If the bolts could not be easily installed, attempt to rotate the exhaust camshaft at 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 drive.
- Relieve the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the piston for the chain tensioner and tensioning rail and press in, 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 TDC for cylinder 5. Refer to => [ Valve Timing, Checking ] Adjustments, but do not lock the crankshaft using the locking pin (T40069).
- Rotate the crankshaft so the camshaft clamp (T40070) can be easily installed to the camshafts, as illustrated.
- Tighten the bolts for the camshaft clamp (T40070) to 20 Nm.
Remove the sprockets from the camshafts.
- Release the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the piston for the chain tensioner and tensioning rail and press in, 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.
- 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 will rest on the pistons.
Valve Timing, Adjusting
• The crankshaft is secured by the locking pin (T40069)
• The camshafts are secured by 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 to release the tension on the chain tensioner.
- Install the counterhold tool Touareg V10 (T10172) to the exhaust camshaft sprocket - 4 -.
• A second mechanic is required for the following steps.
- Rotate the counterhold tool Touareg V10 (T10172) in the - direction of the arrow - to preload the timing chain.
- Tighten the intake camshaft bolt - 2 - first, and then the exhaust camshaft bolt - 3 - to 60 Nm.
Then tighten the bolts - 2 and 3 - and additional 90° (1/4) turn further.
• 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 -.
- Rotate the crankshaft 2 revolutions in engine rotation directions and lock it in place. Refer to => [ Crankshaft, Locking ] Procedures. The crankshaft is locked to check/adjust the valve timing.
- Check the valve timing. Refer to => [ Valve Timing, Checking ] Adjustments.
If the valve timing is not correct:
- Loosen the camshaft sprockets again and adjust the valve timing again (replace the camshaft sprocket 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 ] Service and Repair.