Valve timing, adjusting

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Valve Timing, Adjusting

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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

Sealing compound AMV 176 501

Work procedure

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

Route lines of all types (e.g. for fuel, hydraulic, EVAP system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

NOTE:

The following work sequence is described with engine removed. The adjustments required depend on how far the engine has been disassembled. The oil pan is removed and may only be installed after the sealing flange has been installed.

Install roller chain and chain tensioner with tensioning plate for intermediate shaft drive:

Fig 2: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft

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Adjust position of crankshaft relative to intermediate shaft. To position: Align ground-down tooth of drive chain sprocket - B - with bearing joint (TDC cyl. 1).
Install both bolts without collar for guide rail - 2 - and tighten to 10 Nm.

NOTE:

Note direction of rotation of used chains Marking roller chains

Install guide rail - 2 - with roller chain - 1 - and both chain sprockets - 3 - and - 4 -. Marking on roller chain sprocket - 4 - must align with notch - C - or - D - on thrust washer of intermediate shaft.

During installation make sure that the roller chain runs completely straight in the guide rail from the crankshaft to the intermediate shaft.

Fig 3: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft

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Tighten chain sprockets - 3 - and - 4 - on the intermediate shaft by hand.

NOTE:

Be aware that all chain sprocket securing screws/bolts must be replaced.

Install chain tensioner on opposite side.
Release locking splines of chain tensioner - A - with a small screwdriver and tensioning rail pressed against chain tensioner.
Install chain tensioner in this position and tighten to 8 Nm.

Fig 4: Loosening/Tightening Securing Bolt, Using Counter-Holder T10069 To Hold Vibration Damper

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Lock vibration damper with counter-holder T10069.

Fig 5: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft

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Tighten new securing bolt for intermediate shaft chain sprockets - 3 - and - 4 - to 60 Nm + 90 ° (1/4 turn). (The additional turn may be performed in several steps.)
Remove counter-holder T10069.
Check position of crankshaft - B - to intermediate shaft - C - or - D - again.
Set engine again to TDC cyl. 1.

Install roller chain for camshaft drive:

Position camshafts in cylinder head to TDC No. 1 cylinder.

Fig 6: Locating Counter-Hold Area On Camshaft

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NOTE:

If necessary use 32 mm open end wrench to turn camshafts - arrow - to the correct position. Camshaft bar T10068 A must not be installed during this process.

Fig 7: Identifying Camshaft Bar T10068 Engage In Both Shaft Grooves

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The camshaft bar T10068 A must engage in both shaft grooves.

NOTE:

If the cylinder head is removed:
Install cylinder head, refer to Cylinder head, removing and installing .

Place camshaft roller chain on intermediate shaft chain sprocket.
Route chain between tensioning rail and guide rail toward control housing.

NOTE:

The camshaft bar T10068 A remains installed.
For this version of camshaft adjustment, the exhaust and intake camshaft adjusters can be turned in two directions. When installing, make sure both camshaft adjusters are turned in direction of - arrow - until limit stop.
The distance between the intake and exhaust camshaft adjuster markings "24E" to "32A" amounts to exactly 16 rollers of the camshaft roller chain.

Fig 8: Turning Sensor Wheel At Intake Camshaft Adjuster To The Right

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Turn sensor wheel - 1 - at intake camshaft adjuster to the right - arrow - until limit stop, and fasten adjuster hand-tight in this position to intake camshaft with camshaft roller chain installed.

Fig 9: Locating Guide Rail & Bolts

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Make sure that the camshaft roller chain rests against the guide rail - 1 - tightly and does not hang through.

Fig 10: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing

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The marking "24E" - A - on the camshaft adjuster must be aligned with the notch - arrow - of control housing - C -.
From the marking "24E" on adjuster count exactly 16 rollers on control chain toward right and mark the roller with a colored marker.

Fig 11: Turning Sensor Wheel Of Exhaust Camshaft Adjuster To Right

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Turn sensor wheel - 1 - of exhaust camshaft adjuster to right - arrow - until limit stop and hold adjuster with sensor wheel in this position.

Fig 12: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing

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Place exhaust camshaft adjuster with marking "32A" into camshaft roller chain, positioned exactly so that the 16 pre-counted rollers rest between markings "24E" and "32A" - 1 - and - 2 -.
Fasten exhaust camshaft adjuster to camshaft hand-tight.

Continued for engine codes BJS

Remove camshaft bar T10068 A.
Turn over crankshaft twice in direction of engine rotation and check valve timing, refer to Valve timing, checking .

NOTE:

When turning the crankshaft, the tensioning rail must be pressed by hand against the camshaft roller chain at the chain tensioner, so that the camshaft roller chain does not jump over!

If marks do not align:

Repeat valve timing adjustment procedure.

If marks align:

Fig 13: Locating Counter-Hold Area On Camshaft

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Hold respective fastening camshaft tightly with an open-end wrench 32 mm - arrow -.

NOTE:

Camshaft bar T10068 A must not be installed during this process.

Fig 14: Identifying Intake And Exhaust Camshaft Adjusters And Securing Bolt

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Tighten new securing bolt - 3 - for intake and exhaust camshaft adjusters - 4 - and - 2 - to 60 Nm + 90 ° (1/4 turn). (The additional turn may be performed in several steps.)
Coat sealing surface of sealing flange with sealing compound "AMV 176 501" and install. Tighten bolts to 8 Nm.
Prepare cylinder head gasket for installation Preparing cylinder head gasket for installation , under Preparing cylinder head gasket for installation
Coat sealing surface of cover with sealing compound "AMV 176 501".

Lubricate O-ring for oil channel seal and install with oil seal into cover.
Install cover, insert all fastening bolts and lightly tighten.
First fasten bolts M8 to 23 Nm, then fasten bolts M6 to 8 Nm.
Install camshaft roller chain tensioner and fasten to 40 Nm.

Turn over crankshaft twice in direction of engine rotation and check valve timing again.
Install cylinder head cover and intake manifold, refer to Cylinder head cover, removing and installing .