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  Adapter -10 - 222 A /28- t  To avoid damaging wing edges, apply adhesive tape -arrow- to bottom areas of both adapters -10 - 222 A /28-.

t  Torque wrench (40... 200 Nm) -V.A.G 1332- t  Sealant D 176 501 A1 Removing –  Remove engine splash guard or noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front right wheel housing liner: → General body repairs, exterior; Rep. gr.66. –  Remove air filter → Chapter. –  Mark direction of rotation of poly V-belt and remove it → Chapter. Vehicles with air conditioner

–  Remove air conditioner compressor from bracket with refrigerant lines still connected → Heating, air conditioning; Rep. gr.87.   Note t  The air conditioning system lines must not be opened. t  Observe additional information → Chapter. –  Release and remove electrical connector -1- for air conditioner compressor regulating valve -N280- from air conditioner compressor. –  Remove bolts -arrows- for air conditioner compressor. –  Tie up air conditioner compressor together with refrigerant hoses to body. Continuation for all vehicles –  Remove alternator → Electrical system; Rep. gr.27. –  Remove expanded plastic components or seals in area of wing edges.

–	Remove plenum chamber cover -1- in exterior area → Body - front; Rep. gr.50.

–	Place support bracket -10 - 222 A- with adapter -10 - 222 A /8- behind bonnet stay.

–  Place adapter -10 - 222 A /8- behind bend -2-.   Note Plenum chamber cover is in contact with adapters -10 - 222 A /8-.

–  Hook support bracket -10-222 A- into suspension eyes. –  Take up weight of engine and remove bolts -arrows-. –  Remove coolant pump belt pulley → Chapter. –  Remove sump → Chapter.

–  Loosen pulley bolt. Hold belt pulley with counterhold -3415- and -3415/1-.

–  Undo socket bolts of valve timing housing. –  Undo the marked socket bolts -arrows-. –  Remove timing case.   Note Crankshaft bearing bush remains in sealing flange. Installing Install in reverse order. In the process, note the following:   Note The 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  Sealant spots must have a diameter of 10 mm and a thickness of approx. 1 mm. 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-. Renewing crankshaft oil seal, belt pulley end → Chapter. –  Fit new gasket onto dowel pins. –  Screw two -M6x80- studs into cylinder head and cylinder block to improve guidance. –  Fit timing case 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. Tighten securing bolts.

Specified torque:

Component	Specified torque
M6 bolt	10 Nm
M10 bolt	50 Nm
Air conditioner compressor to bracket	23 Nm
V-belt pulley	→ Chapter
Engine mounting 1.6l petrol engine	→ Chapter
Coolant pump belt pulley	→ Chapter
Oil sump	→ Chapter