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- or dial gauge adapter -T10170 A-

t	Camshaft clamp -T10171 A-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t	Torque wrench -V.A.G 1601-

t	Counterhold tool -3415-

t	Locking pin -T10340-

t	Torque wrench -V.A.G 1331-

t  Spark plug socket and extension -3122 B- Procedure –  Remove timing case → 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 cylinder 1. To do this, use puller -T10094 A- and spark plug wrench 3122 B.

–  Screw dial gauge adapter -T10170- into spark plug hole to stop. –  Insert dial gauge -VAS 6079- together with extension -T10170/1- as far as it will go and secure in place with the self-locking nut -arrow-. –  Turn crankshaft in engine direction of rotation to TDC for No. 1 cylinder: Make a note of the position of the dial gauge's small pointer. –  Then, turn crankshaft back 45° in direction opposite to engine's direction of rotation.

–  Press tensioning guide rail -1- in direction of arrow and lock piston with locking pin -T40011-.

–  Mark direction of rotation of timing chain -3- using coloured felt tip marker pen. –  Undo bolts -2- and -4- and remove chain sprockets -1- and -5- together with timing chain -3-. Use the counterhold tool -T10172- for counterholding. –  Re-fit chain sprockets -1- and -5-. –  Replace bolts -2- and -4- and tighten to 50 Nm (using counterhold tool -T10172-). –  Remove sealing cover from camshaft housing → Chapter.

–  Turn inlet and exhaust camshafts until camshaft clamp -T10171 A- can be inserted 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 A-. –  Loosen the bolts of the camshaft sprockets. It is essential to use the counterhold tool-T10172- to do this.   Note The camshaft clamp -T10171 A- must not be used as a counterhold. –  Remove a camshaft sprocket. –  Place the timing chain on the camshaft sprockets, taking into account the running direction, and then re-fit the removed camshaft sprocket. –  Tighten camshaft bolts until camshaft sprockets can still just be turned on camshafts. –  Tension timing chain by removing locking pin -T40011-.

–  Turn crankshaft in engine direction of rotation to TDC for No. 1 cylinder: Permissible deviation from TDC for 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 for No. 1 cylinder.

–  Undo the screw plug -arrow- in the crankcase. –  Screw threaded locking pin -T10340- into crankcase as far as it will go. –  Tighten threaded locking pin -T10340- to 30 Nm.

Locking pin -T10340- locks crankshaft in direction of engine rotation.

–  Hold camshaft sprockets -1- and -5- in this position with counterhold -T10172- then tighten bolts -2- and bolt -4- to 50 Nm.   Note When tightening the camshaft bolts, make sure that the crankshaft does not turn. The timing chain -3- must remain tensioned on both sides. –  Remove camshaft clamp -T10171 A-.

–  Unscrew threaded locking pin -T10340- from crankcase. –  Turn crankshaft 2 turns in engine direction of rotation to TDC for No. 1 cylinder. Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.

–  Insert camshaft clamp -T10171 A- as far as stop in camshaft openings. If camshaft clamp -T10171 A- cannot be fitted: –  Repeat the adjustment. If camshaft clamp -T10171 A- can be inserted:

–  Screw threaded locking pin -T10340- into crankcase as far as it will go. –  Tighten threaded locking pin -T10340- to 30 Nm.

–  Remove camshaft clamp -T10171 A-. Hold camshaft wheels with counterhold -T10172- and tighten bolts -2- and -4- a 1/4 turn (90°) further with a rigid wrench.   Note Camshaft sprockets must not move on camshaft whilst tightening. –  Turn crankshaft again 2 turns in engine direction of rotation to TDC for No. 1 cylinder. Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.

–  Insert camshaft clamp -T10171 A- as far as stop in camshaft openings. If camshaft clamp -T10171 A- cannot be fitted: –  Repeat the adjustment. Further assembly is basically the reverse of the dismantling sequence. In the process, note the following:   Note The locking pin -T10340- remains in the crankcase until the crankshaft pulley is installed. t  Install valve timing housing → Chapter. t  Install poly V-belt → Chapter. t  Renew oil seals for camshaft sealing cover and oil them before fitting.