Checking and adjusting basic mechanical setting: Audi 2.4 D (AAS)

Special tools and workshop equipment required

Mandrel 2064
Setting bar 2065 A
Counterhold 3036

Test requirements:

Toothed belt tension for camshaft OK

=> 5 cyl. Diesel Engine, Mechanical Components (2.4 l Engine); Repair group 13; Dismantling and assembling engine
5 cyl. Diesel Engine, Mechanical Components (2.4 l Engine)
Dismantling and assembling engine

Remove the cylinder head cover.

=> 5 cyl. Diesel Engine, Mechanical Components (2.4 l Engine); Repair group 15; Dismantling and assembling cylinder head
5 cyl. Diesel Engine, Mechanical Components (2.4 l Engine)
Dismantling and assembling cylinder head

Test sequence

Remove the toothed belt guard for injection pump drive.

Turn crankshaft to TDC of No. 1 cylinder -arrow-.
The -O- mark on the flywheel must be located under the edge of the inspection hole...

...at the same time, the marks on the injection pump sprocket and the injection pump must align -arrows-.

Lock injection pump sprocket using mandrel 2064.
Unscrew securing bolt of injection pump drive wheel at camshaft, using counterhold 3036 and ring spanner attachment V.A.G 1332/7.
Mark direction of rotation of toothed belt with chalk or felt pen.
Remove the drive wheel and toothed belt from the camshaft.

If engine timing is OK, it must be possible to insert the setting bar 2065 A into the groove on the rear of the camshaft.

Notes:

If the groove on the camshaft is concealed by the top edge of the cylinder head, rotate the crankshaft a further revolution.
Loosening of the injection pump drive sprocket always requires adjustment of the start of delivery of the injection pump => Page
23-19
. This also applies if engine timing does not require re-adjustment.

Adjusting

If the setting bar cannot be inserted, engine timing must be adjusted as follows:

Rotate the crankshaft until the setting bar 2065 A can be inserted.

Turn camshaft until one end of setting bar 2065 A contacts the cylinder head.
Measure the clearance created at the opposite end using a feeler gauge.
Insert a feeler gauge corresponding to half the clearance between the setting bar and the cylinder head.
Turn camshaft until the setting bar lightly contacts the feeler gauge.
Insert a second feeler gauge corresponding to half the clearance between the setting bar and the cylinder head at the other end.
Remove the upper toothed belt guard for camshaft drive.

Note:

When loosening and tightening the camshaft sprocket, never use the setting bar to counterhold. Counterhold using 3036.

Loosen the securing bolt of the camshaft sprocket 1/2 turn. Release camshaft sprocket from camshaft taper by tapping (pin through hole on rear toothed belt guard) using hammer.

Turn crankshaft to TDC of No. 1 cylinder -arrow-.
Tighten the bolt of the camshaft sprocket as follows.
Bolt with strength rating 8.8: tighten to 85 Nm.
Replace bolt with bolt tightness 10.9 and tighten to 30 Nm + 90°

Note:

When loosening and tightening the camshaft sprocket, never use the setting bar to counterhold. Counterhold using 3036.

Remove setting bar.
Install the injection pump drive sprocket and toothed belt and check toothed belt tension =>Page
23-11
.
Check start of delivery of injection pump and adjust as necessary => Page
23-19