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 (5…50 Nm) -V.A.G 1331-

t	Spark plug socket and extension -3122 B-

Procedure –  Drain coolant → Chapter.

–  Remove securing bolts -1- from engine cover panel. –  Detach coolant hoses -2- at engine cover panel and pull engine cover panel upwards.

–  Pull coolant hoses off coolant pipe -1- and unscrew coolant pipe from camshaft housing and from cylinder block from below.

–  Release and pull off connector -2-. –  Remove oil pressure switch -F1--1-. –  Remove valve timing housing → 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 No. 1 cylinder. Use puller -T10094 A- and spark plug socket and extension 3122 B → Chapter.

–  Screw dial gauge adapter -T10170- into spark plug hole to stop. –  Screw dial gauge -VAS 6079- and extension -T10170/1- in to stop and lock in position with lock nut -arrow-. –  Turn crankshaft in direction of engine rotation, to TDC for No. 1 cylinder. Note position of small needle on dial gauge. –  Then turn crankshaft back 45° opposite direction of engine 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.   Note Camshaft adjuster centre bolt -2- has a left-hand thread. –  Unscrew bolts -2- and -4- and remove camshaft adjuster -1- together with timing chain -3-. Counterhold using counterhold -T10172-. –  Install camshaft adjuster -1- again. –  Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt -4- to 50 Nm (use counterhold -T10172-).   Caution Before using camshaft clamp -T10171 A- you must check that the pins on the tool project by at least 7 mm. If this is not the case, the camshaft clamp is defective and must be renewed. The camshaft clamp must not be positioned using any kind of hammer.

–  Turn inlet and exhaust camshafts until camshaft clamp -T10171 A- can be pushed 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.

–  Screw an M6 bolt hand-tight into corresponding bore -arrows- (but do not tighten) to secure camshaft clamp -T10171 A-.   Note Note that there are different securing points for the camshaft clamp -T10171 A-. –  Remove camshaft sprocket bolts. It is absolutely necessary to use counterhold -T10172- for this.   Note The camshaft clamp -T10171 A- must not be used as a counterhold. –  Remove one camshaft sprocket. –  Place timing chain over camshaft sprockets, observing chain direction of rotation, and install camshaft sprocket again. –  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.

–  Release and pull off connector -1-. –  Remove bolt -3- and detach continued coolant circulation pump -V50-.

–  Unscrew plug -arrow- from crankcase. –  Screw locking pin -T10340- to stop into crankcase. –  Tighten 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 bolt -2- (left-hand thread) to 40 Nm and bolt -4- to 50 Nm.   Note Crankshaft must not move and timing chain -3- must remain tensioned on both sides when tightening camshaft bolts. –  Remove camshaft clamp -T10171 A-.

–  Unscrew 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.   Caution Before using camshaft clamp -T10171 A- you must check that the pins on the tool project by at least 7 mm. If this is not the case, the camshaft clamp is defective and must be renewed. The camshaft clamp must not be positioned using any kind of hammer.

–  Insert camshaft clamp -T10171 A- to stop in camshaft openings. If camshaft clamp -T10171 A- cannot be fitted: –  Repeat adjustment. If camshaft clamp -T10171 A- can be fitted:

–  Screw locking pin -T10340- to stop into crankcase. –  Tighten locking pin -T10340- to 30 Nm.

–  Remove camshaft clamp -T10171 A-, hold camshaft sprockets with counterhold -T10172- and tighten bolts -2- (left-hand thread) and -4- a 1/4 turn (90°) further with a rigid wrench.   Note Camshaft adjuster centre bolt -2- has a left-hand thread.   Note Camshaft sprockets must not move on camshaft whilst tightening. 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 control housing → Chapter. t  Installing crankshaft pulley → Chapter. t  Install poly V-belt → Chapter. t  Renew oil seals for camshaft sealing cover and oil them before fitting. t  Specified torque for continued coolant circulation pump -V50-: 10 Nm t  Specified torque for oil pressure switch -F1-: 25 Nm. t  Fill coolant system with coolant → Chapter.