Volkswagen Workshop Service and Repair Manuals

Installing (adjusting valve timing)   Note t  The toothed belt may only be adjusted on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature. t  If the tensioning roller is to be renewed, the engine bracket always has to be removed. t  Removing and installing engine support (Golf, Passat) → Chapter t  Removing and installing engine support (Touran) → Chapter t  Removing and installing engine support (Golf Plus) → Chapter t  Removing and installing engine support, (Polo) → Chapter t  Renew securing bolts for camshaft pulley and high-pressure pump pulley. Tensioning roller A:

l  Tensioning roller must be locked with locking tool -T10265- and secured to right stop.

l  Crankshaft is locked using crankshaft stop -T10050-. Tensioning roller B:

–  Place tensioner for tensioning roller in 9 o'clock position. –  Secure tensioning roller with 2 - 4 Nm.

Crankshaft is locked using crankshaft stop -T10050-. Continuation for both tensioning rollers   Note If necessary, turn camshaft hub with counterhold -T10172- and adapters -T10172/4- until camshaft can be secured in position. To do this, hand-tighten at least one securing bolt -1-.

–  Lock camshaft hub with locking pin -3359-. To do this, slide locking pin through outer free elongated hole into hole in cylinder head.

–  Loosen bolt which had been tightened only hand-tight. Loosely tightened bolts -arrows-. It should just be possible to turn camshaft toothed belt pulley without axial movement.   Note If necessary, turn hub of high-pressure pump at bolt heads with screwdriver until it can be secured in position.

Positioning hub of high-pressure pump

–  Lock hub of high-pressure pump with locking pin -3359-. To do this, slide locking pin into adjustment hole outside toothed belt pulley. Loosely tightened bolts -1-. It should just be possible to turn high-pressure pump toothed belt pulley without axial movement.

–  Turn camshaft pulley -3- and toothed belt pulley of high-pressure pump -5- in their elongated holes clockwise to stop. –  Fit toothed belt in sequence described: 1 -  Crankshaft toothed belt pulley 2 -  Tensioning roller 3 -  Camshaft toothed belt pulley 4 -  Coolant pump toothed belt pulley 5 -  High-pressure pump toothed belt pulley 6 -  Idler roller Tensioning roller A: –  Loosen tensioning roller securing nut and pull out locking tool -T10265-.   Note

Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.

–  Screw eccentric of tensioning roller clockwise carefully using angled screwdriver -T10264-. Indicator -2- must be roughly past the centre of the gap in the base plate (rectifies itself during pretensioning). Ensure that securing nut -1- does not turn as well. –  Hold tensioning roller in this position and tighten tensioning roller securing nut as follows: 20 Nm and 45° further.

–  Apply counterhold -T10172- as shown. Press counterhold -T10172- in direction of arrow, keeping camshaft toothed belt pulley under tension. –  In this position, first tighten securing bolts -1- of camshaft pulley and of toothed belt pulley for high pressure pump by hand and then tighten to 20 Nm. Tensioning roller B:

–  Carefully turn eccentric on tensioning roller counter clockwise using angled screwdriver -T10409-. Indicator -2- must be roughly past the centre of the gap in the base plate (rectifies itself during pretensioning).

Markings on tensioning element and tensioning roller -arrow- are now almost aligned. Ensure that securing nut -1- does not turn as well. –  Hold tensioning roller in this position and tighten tensioning roller securing nut -1-: 20 Nm and turn 45° further.

–  Apply counterhold -T10172- as shown. Press counterhold -T10172- in direction of arrow, keeping camshaft toothed belt pulley under tension.

–  Tighten securing bolts -arrows- for camshaft pulley hand-tight at first and then to 20 Nm.

–  Tighten securing bolts for high-pressure pump toothed belt pulley hand-tight at first and then to 20 Nm. Continuation for both tensioning rollers –  Remove locking pins -3359- and crankshaft stop -T10050-. –  Turn crankshaft at least 2 rotations in engine direction of rotation and set again to TDC no. 1 cylinder. –  Fit crankshaft stop -T10050- again to crankshaft belt pulley.

–  Now turn crankshaft in engine direction of rotation until pin of crankshaft stop -arrow- engages in sealing flange from rotational movement.   Note

During the following checking procedure, only the camshaft and crankshaft must be secured in position. It is very difficult to find the securing position of the high-pressure pump hub again. However, a slight deviation -arrow- does not influence the engine operation. –  Check if: t  Camshaft hub can be locked with locking pin -3359-. t  Tensioning roller indicator is centred or maximum 5 mm to right of base plate notch. If camshaft hub cannot be locked: –  Pull crankshaft stop -T10050- back until pin uncovers hole. –  Turn crankshaft in opposite direction of engine rotation slightly past TDC. –  Now turn crankshaft slowly in direction of engine rotation until camshaft hub can be secured in position. –  After locking, loosen securing nuts of crankshaft toothed belt pulley. If pin of crankshaft stop -T10050- is standing on left next to hole:

–  Turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning. –  Tighten securing bolts of camshaft toothed belt pulley by hand first and then tighten to 20 Nm. If pin of crankshaft stop -T10050- is standing on right next to hole: –  Slightly turn crankshaft in opposite direction of engine rotation. –  Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning. –  Tighten securing bolts of camshaft toothed belt pulley by hand first and then tighten to 20 Nm. Continuation –  Remove locking pin -3359- and crankshaft stop -T10050-. –  Turn crankshaft at least 2 rotations in engine direction of rotation and set again to TDC no. 1 cylinder. –  Repeat check. –  If camshaft hub can be secured in position, tighten securing bolts as follows:

t  Camshaft toothed belt pulley: turn 45° further. Counterhold with counterhold -T10172- and adapters -T10172/4-.

t  Counterhold high-pressure pump toothed belt pulley with counterhold -T10172- and adapters -T10172/8-. 20 Nm, do not turn any further. –  Install centre and lower parts of toothed belt guard. –  Install belt pulley vibration damper: specified torque 10 Nm + 90° further. –  Install poly V-belt. –  Install upper toothed belt guard. Further assembly is basically the reverse of the dismantling sequence. In the process, note the following: t  Ensure that fuel hose connections are tight. t  Do not interchange supply line and return line (return line blue or with blue marking, supply line white). –  Install wheel housing liner. –  Install noise insulation. → General body repairs, exterior; Rep. gr.50.