Volkswagen Workshop Service and Repair Manuals

Checking valve timing

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Torque wrench (5…50 Nm) -V.A.G 1331-

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-

Note The mounting points for securing the camshaft clamp were modified. A new special tool designated camshaft clamp -T10171 A- has been introduced. Previous camshaft clamp -T10171- can continue to be used if modified as described below.

–  Place template -1- onto camshaft clamp -T10171- as shown. –  Mark camshaft clamp -T10171- at mark -2- using a centre punch. –  Drill through camshaft clamp -T10171- using a 7 mm bit. –  Deburr hole on both sides. –  Additionally mark tool designation -T10171- with an »A«. Test 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 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.

The holes -arrows- in the camshaft must align as shown. Otherwise turn crankshaft one rotation (360°) further.   Note t  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. t  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- to stop in camshaft openings. Locking pins -arrows 1- must engage in holes -arrows 2-. Inscription „TOP“-arrow 3- must be readable from above. If camshaft clamp -T10171 A- cannot be fitted into camshaft openings to stop, then timing is incorrect and must be readjusted → Chapter. Timing is OK if camshaft clamp -T10171 A- can be fitted into camshaft openings to stop. Further assembly is basically the reverse of the dismantling sequence. In the process, note the following: t  Renew oil seals for camshaft sealing cover and oil them before fitting. t  Specified torque for oil pressure switch -F1-: 25 Nm. –  Fill coolant system with coolant → Chapter.