Volkswagen Workshop Service and Repair Manuals

(Adjusting valve timing)

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ 10-222A Engine support bracket with legs 10-222A/1
• ◆ 2065 A Adjustment bar
• ◆ V.A.G 1331 Torque wrench (5 ... 50 Nm)
• ◆ V.A.G 1332 Torque wrench (40 ... 200 Nm)
• ◆ T10004 Two hole pin wrench
• ◆ T10172 Counter-Bracket

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ T10172/3 Pin

Notes:

If you only have to take the toothed belt off the camshaft sprocket, e.g. when removing the camshaft or the cylinder head, the following must be considered:

• ◆ Engine bracket, tensioning element for ribbed belt, vibration damper/belt pulley and toothed belt guard (apart from upper part) can remain fitted.
• ◆ To remove toothed belt from camshaft sprocket unscrew tensioning roller and slide up to the engine bracket.

Retrofit counter-bracket T10172

• ‒ → Unscrew pins T10172/1.
• ‒ Screw pins T10172/3 in and tighten them.

Removing

• ‒ Remove the engine cover.
• ‒ Remove right-hand noise insulation.

=> General body repairs, exterior; Repair group 50; Noise insulation (petrol engine) - Assembly overview

• ‒ Remove poly V-belt .
• ‒ Remove tensioning element for poly V-belt.
• ‒ Remove intake manifold upper part => Page 24-24.
• ‒ Remove toothed belt guard -upper part.
• ‒ Remove coolant expansion tank (supply hose remains connected, close union for return supply hose).
• ‒ Remove reservoir of power assisted steering (hoses remain connected).
• ‒ Remove connector of camshaft timing adjustment valve.
• ‒ Remove cylinder head cover.

• ‒ → Fit support 10-222A with legs 10-222A/1 as shown.

• ‒ → Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body and assembly mounting/body mounting -arrows- and remove assembly mounting complete.

Notes:

• ◆ Only remove engine mounting when the engine is secured with the support bracket 10-222A.
• ◆ The engine bracket must be only released when the engine mounting is removed.

• ‒ → Remove vibration damper/belt pulley.

• ‒ → Remove engine bracket from cylinder block.

Note:

When loosening the front engine mounting bolt the engine must be raised slightly with the support device.

• ‒ Remove toothed belt guard centre and lower parts.
• ‒ Mark D.O.R. of toothed belt.

• ‒ → Turn crankshaft until the camshaft is set to TDC No. 1.

• The adjustment bar 2065 A must be pushed into the slot of the camshaft.

• ‒ Then remove the tool.
• ‒ Release tensioner and take off toothed belt.
• ‒ Turn crankshaft against of engine D.O.R. 45°.

Installing

Prerequisites

• ● The pistons must not be positioned at TDC.
• ● The engine must only be hand touch warm.

Installing toothed belt and tensioning toothed belts

Notes:

• ◆ When the camshaft is turned, the crankshaft must not be at TDC. Danger of damage to valves or piston crowns.
• ◆ Do never use the adjustment bar 2065 A as counter hold when loosening and tightening the camshaft sprocket! Use counter -bracket T10172 with pin T10172/3.

• ‒ → Place a flat container under the camshaft sprocket, to collect oil leaking out when the sealing plug -1- is loosened.
• ‒ Unscrew the sealing plug -1- carefully and collect the leaking oil. When doing this do not rotate crankshaft, if possible.

• To loosen the sealing plug use counter-bracket T10172 with pin T10172/3, if necessary.

• ‒ Clean oil from camshaft sprocket with a cloth.

• ‒ → Remove camshaft bolt. When doing this do not rotate crankshaft, if possible.

• To loosen the camshaft bolt use counter-bracket T10172 with pin T10172/3.

• ‒ Take the camshaft sprocket off the camshaft and clean it.

Notes:

• ◆ The teeth on the crankshaft and the crankshaft seal contact surface must be free of oil.
• ◆ In this condition, it is recommended to renew prophylactically the crankshaft seal (little expenditure) => Page 15-33, Servicing valve gear.

• ‒ Fit the camshaft sprocket again on the camshaft and screw camshaft bolt into.

• ‒ → Set camshaft to TDC No. 1. and let the adjustment bar 2065 A inserted.
• ‒ Loosen camshaft bolt until the camshaft sprocket can be turn by hand. To do this use counter-bracket T10172 with pin T10172/3.
• ‒ Place toothed belt on crankshaft pulley and coolant pump (observe D.O.R.).
• ‒ Install tensioning toothed belt centre and lower parts and belt pulley/vibration damper.

• ‒ → Turn crankshaft in engine D.O.R again at TDC No. 1 Cyl.. The notch -2- on the belt pulley/vibration damper must align with the notch -1- on the toothed belt guard, upper part.
• ‒ Turn the camshaft sprocket so that the counter-bracket T10172 with pin T10172/3 can be inserted.
• ‒ Place toothed belt on tensioning roller and camshaft sprocket.

• ‒ → Turn the tensioning roller on the eccentric with the two hole pin wrench (T10004) five times onto limit stop in both directions.
• ‒ Tensioning toothed belt. To do this turn eccentric to left (direction of arrow) with two hole pin wrench (T10004) onto limit stop.
• ‒ Then release tension on toothed belt until the notch -1- and indicator -2- align (use mirror).
• ‒ Tighten securing nut to 20 Nm.
• ‒ Check TDC of crankshaft again, correct if necessary.

Note:

If the crankshaft is positioned after TDC No. 1 cylinder turn the crankshaft again a bit against the engine direction of rotation and set to TDC No. 1 cylinder.

• ‒ → Hold crankshaft sprocket with the counter-bracket T10172 (pin T10172/3) and tighten camshaft bolt to 40 Nm.
• ‒ Remove setting bar 2065 A.
• ‒ Counter camshaft sprocket and tighten camshaft bolt to 130 Nm.

• ‒ → Turn crankshaft two rotations in engine D.O.R. until the setting bar 2065 A can be insert. When doing this it is essential that the last 45° (1/8 turn) is performed without stopping.

Note:

If the crankshaft has been turned to far, turn the crankshaft 1/4 turn back and set the camshaft to TDC No. 1 cylinder again (insert the adjustment bar 2065 A into the camshaft).

• ‒ → Check TDC of the crankshaft.

The notch -2- on the vibration damper/belt pulley must be positioned -a- max. 5 mm after the TDC marking -1- on the toothed belt guard lower part.

If the crankshaft is not in this area:

• ‒ Repeat adjustment.

If the crankshaft is in this area:

• ‒ → Check toothed belt tension again and if necessary adjust.

• Specification: Indicator and notch align

Continuation, install toothed belt complete

• ‒ → Install sealing plug -1- (renew O ring).
• Torque setting: 25 Nm
• ‒ Fit engine mounting to cylinder block.
      Prescribed torque 45 Nm

Notes:

• ◆ Insert bolts into engine bracket before installing engine bracket.
• ◆ Tighten all bolts of the engine bracket, with the tightening torque instructed, before installing the engine mounting.

• ‒ Install engine assembly mountings complete.
• ‒ Align assembly mountings for engine and gearbox .

Tightening torques for assembly mounting

.

• ‒ Remove engine support device10-222 A.
• ‒ Install toothed belt guard - upper part.
• ‒ Install ribbed belt tensioning element.
      Tightening torque: 25 Nm
• ‒ Install poly V-belt => page 13-11.
• ‒ Install coolant expansion tank.
• ‒ Install power steering reservoir.
• ‒ Installing cylinder head cover.
• ‒ Connect connector of camshaft timing adjustment valve.
• ‒ Install intake manifold upper part=> Page 24-24.
• ‒ Start engine and run briefly at idling speed (oil pressure increase in camshaft adjustment).
• ‒ Install right-hand sound insulation:

=> General body repairs, exterior; Repair group 50; Noise insulation (petrol engine) - Assembly overview

• ‒ Check engine oil level and top up, if necessary.
• ‒ Install engine cover.