Valve Timing, Checking

Special tools and workshop equipment required

Electronic Torque Wrench 3-60Nm: VAS6583
Torque Wrench 1783 - 1/4" Drive Ratchet: VAS6234
Crankshaft Locking Pin: T10340
Camshaft Lock: T10494
Assembly Tool: T10487
Socket T30: T10405
Intake Manifold Release Tool: T10527 (not illustrated)
Intake Manifold Release Tool: T10527/1 (not illustrated)
Screwdriver (shaft length at least 250 mm) (not illustrated)

Procedure

This procedure also shows the engine at "TDC position for cylinder 1".

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the resonator for the intake air scoop. Refer to INTAKE AIR SCOOP RESONATOR, REMOVING AND INSTALLING .

-- Remove the air duct hose on the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the air duct pipe. Refer to AIR DUCT PIPE, REMOVING AND INSTALLING .

-- Remove the Ignition Coil 1 with Power Output Stage -N70- and the cylinder 1 spark plug. Refer to IGNITION COILS WITH POWER OUTPUT STAGES, REMOVING AND INSTALLING .

-- Push the release button and remove the hose -1- from the EVAP canister.

Fig 1: Identifying Hose Bolts

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-- Remove the bolts -arrows- and then remove the crankcase ventilation hose.

-- Open the bracket -1- and remove the coolant hose -2-.

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-- Remove the bolts -arrows- using the : VAS6234 and : T10405 .

Fig 2: Locating Bolts

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-- Remove the support -1- upward.

-- Release and disconnect the connector -2-.

-- Free up the wiring harness -arrows-.

Fig 3: Identifying Upper Belt Cover And Bolts

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-- Remove the bolts -1 and 3- and remove the toothed belt guard -2- for the coolant pump toothed belt.

-- Remove the bolts -arrows- and the cover -1-.

Fig 4: Identifying Coolant Pump Toothed Belt Cover And Bolts

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NOTE:

Risk of chemical damage to the coolant pump seal from oil entry between the coolant pump and the cylinder head.

-- Cover the coolant pump with a clean cloth to catch escaping oil.

Turn the Crankshaft to "TDC" as Follows

NOTE:

There is a risk of damaging the engine!

The : T10340 can contact on the crankshaft in the second position.

The "TDC position" must be checked as described.

-- Insert the screwdriver with a shaft length of at least 250 mm carefully until it contacts the piston crown in the spark plug shaft.

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-- Turn the crankshaft in the direction of engine rotation until the cylinder 1 piston is in "BDC".

The screwdriver moves in direction of -arrow- during this.

-- Continue turning the crankshaft in the direction of engine rotation until the Screwdriver has moved -30 mm- in direction of -arrow-.

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-- Remove the plug for the "TDC" hole in the cylinder block.

Fig 5: Identifying Crankshaft Locking Pin - T10340-

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-- Install the : T10340 all the way into the cylinder block and tighten to 30 Nm.

-- Turn the crankshaft all the way in direction of engine rotation.

The locking pin is touching the crankshaft counterweight.

NOTE:

The : T10340 locks the crankshaft only in the direction of engine rotation.

There Is a Risk of Damaging the Engine

If the : T10340 cannot be installed all the way, then the crankshaft is not in the correct position.
In this case, proceed as follows:
Remove the locking pin.
Turn the crankshaft 90° in the direction of engine rotation.
Install the : T10340 all the way into the cylinder block and tighten to 30 Nm.
Continue to turn the crankshaft in the direction of engine rotation until it stops.
A second technician is needed to check the valve timing

The asymmetrical grooves -arrows upper - on the transmission side on both camshafts must now face upward, as illustrated.
The grooves -arrows- on the exhaust camshaft -A- are accessible through the holes in the drive wheel for the coolant pump.

Fig 6: Locating Grooves
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The grooves -arrows- on the intake camshaft -E- are above the center of the camshaft.

A - Exhaust Camshaft

E - Intake Camshaft

-- If the camshafts are not positioned as described, remove the : T10340 and turn the crankshaft one turn farther and back to "TDC".

NOTE:

It must be easy to insert the : T10494 .

Do not use a hammer to install the camshaft positioning tool.

If the : T10494 cannot be inserted easily:

Vehicles with Two Camshaft Adjusters

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-- Use the Assembly Tool: T10487 to push on the toothed belt in direction of -arrow-.

Vehicles with a Camshaft Adjuster

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-- Use the : T10487 to push on the toothed belt in direction of -arrow-.

Continuation for All Vehicles

-- A second technician is needed for this.

-- Insert the : T10494 all the way into the camshafts while doing so.

Fig 7: Identifying Camshaft Lock

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-- Tighten the bolt -arrow- hand-tight.

If it is not easy to install the camshaft locating tool:

-- Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

If is it easy to install the camshaft locating tool:

-- The valve timing is OK.

There Is a Risk of Damaging the Engine

Make sure the : T10340 and the : T10494 are removed after completing the work.

The rest of the assembly is performed in reverse order of removal, noting the following:

-- Replace the bolts that were tightened with an additional turn.

-- Replace the O-ring for the plug if it is damaged.

Tightening Specifications

Refer to OVERVIEW - TOOTHED BELT
Refer to Figure
Refer to OVERVIEW - CAMSHAFT HOUSING
Refer to OVERVIEW - CRANKCASE VENTILATION
Refer to OVERVIEW - COOLANT PUMP/COOLANT THERMOSTAT
Refer to OVERVIEW - CHARGE AIR SYSTEM