Volkswagen Workshop Service and Repair Manuals

Removing and installing valve timing housing

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Counterhold tool -3415-

t	Pins -3415/1-

t	Torque wrench (5...50 Nm) -V.A.G 1331-

t  Torque wrench (40...200 Nm) -V.A.G 1332- t  Sealant D 176 501 A1 Removing –  Remove engine splash guard. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. Gr.66. –  Mark the direction of rotation of the poly V-belt and remove belt → Chapter. –  Remove air conditioner compressor from bracket with refrigerant lines still connected → Heating, air conditioning; Rep. Gr.87. –  Remove alternator.

–  Install support device -10-222 A- with adapter -10 - 222 A /1- as shown and hook into lifting eye -arrow-.

–  Take up weight of engine and remove securing bolts -arrows-. –  Remove sump → Chapter.

–  Now remove pulley securing bolt. Hold pulley with counterhold tool -3415- and -3415/1-.

–  Remove Allen head bolts for control housing and hexagon bolts indicated by -arrows-. –  Remove valve timing housing.   Note Note that crankshaft bearing bush remains in sealing flange. Installing   Note Note that pulley contact surfaces, securing bolt, bearing bush and crankshaft chain sprocket must be free of oil and grease. –  Clean sealing surfaces carefully. They must be free of oil and grease.   Note t  The valve timing housing is still sealed to the engine with a seal and also sealant D 176 501 A1. t  The sealant D 176 501 A1 is used to prevent leaks between the valve timing housing and the joints -1- and -2-. t  The centre of the sealant must have a diameter of 10 mm and be approximately 1 mm thick. t  Do not apply sealant until directly before the valve timing housing is fitted.

–  Apply sealant D 176 501 A1 to the joints camshaft housing/cylinder head -1- and cylinder head/cylinder block -2-. If new repair set is used, diamond-coated disc (inner diameter 23 mm) must be first pushed onto crankshaft journal to stop. Tightening procedure for poly V-belt pulley securing bolt → Chapter Renew crankshaft oil seal - pulley end → Chapter –  Fit new gasket onto dowel pins. –  When fitting, install two -M6x80- studs into cylinder head and cylinder block as a guide. –  Fit valve timing housing with crankshaft bearing bush simultaneously onto studs, dowel pins and crankshaft journal. –  Tighten valve timing housing securing bolts evenly and diagonally. Ensure that camshaft housing is not canted. Torque settings: M6 bolt to 10 Nm. M10 bolt to 50 Nm. Tightening procedure for poly V-belt pulley securing bolt → Chapter Further assembly is basically the reverse of the dismantling procedure.