Volkswagen Workshop Service and Repair Manuals

Adjusting valve timing

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Dial gauge adapter -T10170-

t	Camshaft clamp -T10171-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t  Spark plug socket and extension -3122 B-

t  Counterhold tool -3415- t  Torque wrench (5…50 Nm) -V.A.G 1331- Procedure –  Removing timing housing (Eos, Golf, Golf Plus, Passat) → Chapter. –  Removing timing housing (Touran) → Chapter. Remove exhaust gas recirculation valve -N18- → Chapter

–  To turn crankshaft, reinstall bearing bush, crankshaft pulley -2- and crankshaft bolt -3- and securely tighten crankshaft bolt (use counterhold 3415). –  Remove spark plug from No. 1 cylinder. Use puller -T10094 A- and spark plug wrench 3122 B.

–  Screw dial gauge adapter -T10170- into spark plug hole to stop. –  Screw dial gauge -VAS 6079- and extension -T10170/1- in to stop and lock in position with lock nut -arrow-. –  Turn crankshaft in direction of engine rotation, to TDC No. 1 cylinder. Note position of small needle on dial gauge. –  Then turn crankshaft back 45° opposite direction of engine rotation.

–  Press tensioning guide rail -1- in direction of arrow and lock piston with locking pin -T40011-. Engine codes BAG, BLP, BLF

–  Mark direction of rotation of timing chain -3- using coloured felt tip marker pen.   Note Camshaft adjuster centre bolt -2- has a left-hand thread. –  Unscrew bolts -2- and -4- and remove camshaft adjuster -1- together with timing chain -3-. Counterhold using counterhold -T10172-. –  Install camshaft adjuster -1- again. –  Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt -4- to 50 Nm (use counterhold -T10172-). Engine codes BKG, BLN

–  Mark direction of rotation of timing chain -3- using coloured felt tip marker pen. –  Unscrew bolts -2- and -4- and remove chain sprocket -1- together with timing chain -3-. Counterhold using counterhold -T10172-. –  Install chain sprocket -1- again. –  Renew bolts -2- and -4- and tighten them to 50 Nm using counterhold -T10172-.

–  Turn inlet and exhaust camshafts until camshaft clamp -T10171- can be pushed into holes in camshaft to stop. Locking pins -arrows 1- must engage in holes -arrows 2-. Inscription „TOP“-arrow 3- must be readable from above.   Note Camshafts must not be pushed axially whilst turning.

–  Install a M6 bolt -arrow- hand-tight (do not tighten) to secure camshaft clamp -T10171-. –  Remove camshaft sprocket bolts. It is absolutely necessary to use counterhold -T10172- for this.   Note Camshaft clamp -T10171- must not be used as a counterhold. –  Remove one camshaft sprocket. –  Place timing chain over camshaft sprockets, observing chain direction of rotation, and install camshaft sprocket again. –  Tighten camshaft bolts until camshaft sprockets can still just be turned on camshafts. –  Tension timing chain by removing locking pin -T40011-.

–  Turn crankshaft in direction of engine rotation to TDC No. 1 cylinder. Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.   Note If crankshaft is turned more than 0.01 mm past TDC, then turn crankshaft back 45° against engine direction of rotation. Then turn crankshaft in direction of engine rotation to TDC No. 1 cylinder. Engine codes BAG, BLP, BLF

–  Hold camshaft sprockets -1- and -5- in this position with counterhold -T10172- then tighten bolt -2- (left-hand thread) to 40 Nm and bolt -4- to 50 Nm. Engine codes BKG, BLN

–  Hold camshaft sprockets -1- and -5- in this position with counterhold -T10172- then tighten bolts -2- and bolt -4- to 50 Nm.   Note Crankshaft must not move and timing chain -3- must remain tensioned on both sides when tightening camshaft bolts. –  Remove camshaft clamp -T10171-. –  Turn crankshaft two rotations in direction of engine rotation to TDC No. 1 cylinder. Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.

–  Insert camshaft clamp -T10171- to stop in camshaft openings. If camshaft clamp -T10171- cannot be fitted –  Repeat adjustment. If camshaft clamp -T10171- can be fitted –  Remove camshaft clamp -T10171-, hold camshaft chain sprockets with counterhold -T10172- and tighten bolts -2- (left-hand thread) and -4- 90° further with a rigid wrench.   Note Camshaft adjuster centre bolt -2- has a left-hand thread.

Engine codes BAG, BLP, BLF

Engine codes BKG, BLN   Note Camshaft sprockets must not move on camshaft whilst tightening. –  Turn crankshaft two rotations in direction of engine rotation to TDC No. 1 cylinder again. Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.

–  Insert camshaft clamp -T10171- to stop in camshaft openings. If camshaft clamp -T10171- cannot be fitted –  Repeat adjustment. Further assembly is basically the reverse of the dismantling sequence. In the process, note the following: t  Installing timing housing (Eos, Golf, Golf Plus, Passat) → Chapter. t  Installing timing housing (Touran) → Chapter. t  Install poly V-belt → Chapter. t  Renew oil seals for camshaft sealing cover and oil them before fitting. t  Install exhaust gas recirculation valve -N18- → Chapter.