Volkswagen Workshop Service and Repair Manuals

Adjusting valve timing   Note t  Sump only needs to be removed on vehicles ► 12.2009. t  In these vehicles, the timing chain can slip off the crankshaft chain sprocket during installation.

Special tools and workshop equipment required

t	Locking pin -T10414-

t	Locking pin -T10340-

t	Torque wrench -VAS 6583-

t	Torque wrench (40 … 200 Nm) -V.A.G 1332-

t	Counterhold tool -T10172-

t	Sealant D 176 501 A1

t	2 studs M6x70 (e.g. bolts with sawn-off head)

Procedure –  Drain coolant → Chapter.

–  Open spring-type clips and pull coolant hoses -1- and -2- off. –  Push catch -3- underneath coolant hoses and pull hoses upwards. –  Put down coolant hoses to rear.

–  Pull both hoses -1- off non-return valve. –  Unscrew securing bolt -2- and pull non-return valve out of cylinder head cover.

–  Remove all securing bolts from valve timing housing cover -1-. –  Remove valve timing housing cover.

–  Remove securing bolts -1- and remove coolant pipe bracket -2-.

–  Unscrew plug -arrow- from cylinder block. –  Screw locking pin -T10340- to stop into crankcase. –  Turn crankshaft in normal direction of rotation until the stop.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as described below. –  Remove locking pin. –  Turn crankshaft 1/4 revolution (90°) in normal direction of rotation. –  Screw locking pin -T10340- to stop into crankcase. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in normal direction of rotation until the stop.

Locking pin -T10340- locks crankshaft in direction of engine rotation.   Caution Sump only needs to be removed on vehicles ► 12.2009. In these vehicles, the timing chain can slip off the crankshaft chain sprocket during installation! –  Remove sump → Chapter.

–  Pull cover -1- off oil pump.

–  Unscrew chain tensioner -arrow- for timing chain.

–  Loosen securing bolt -1- for camshaft chain sprocket. –  Hold camshaft chain sprocket with counterhold tool -T10172-. –  Remove camshaft sprocket together with securing bolt.

–  Place timing chain -1- on cast lug -arrow- in valve timing housing.   Note Cast lug on inside of valve timing housing prevents timing chain from falling down.

–  Position chain sprocket -1- on camshaft and tighten securing bolt -2- to 50 Nm.   Note The camshaft sprocket must be tightened to 50 Nm so that the camshaft can be turned in position as described below. –  Hold camshaft sprocket with counterhold tool -T10172-. –  Then turn crankshaft 1/4 revolution (90°) back counter to direction of engine rotation.   Note Turning crankshaft opposite to normal direction of rotation prevents damage to valves when camshaft is subsequently adjusted.

–  Turn camshaft until grooves -arrows- are in position shown.

–  Insert locking pin -T10414- to stop in cylinder head cover. –  Tighten securing bolt -1- hand tight. –  Turn crankshaft in normal direction of rotation until the stop. –  Remove camshaft sprocket. –  Hold camshaft sprocket with counterhold tool -T10172-.

–  Raise timing chain using assembly tool -T10118-.   Caution Sump only needs to be removed on vehicles ► 12.2009. In these vehicles, the timing chain can slip off the crankshaft chain sprocket during installation! Only vehicles ► 12.2009

–  From underneath, check timing chain -1- is in correct position on crankshaft chain sprocket. All vehicles

–  Place timing chain -1- onto chain sprocket -2-. Timing chain must make contact in area of guide rail -3- and be slightly tensioned. –  Tighten new securing bolt by hand. Timing chain must be guided centrally onto tensioning rail.

–  Tighten chain tensioner -arrow- to 60 Nm.

–  Fit new securing bolt and tighten camshaft sprocket-1- to 50 Nm.   Note Securing bolt is not tightened by a 1/4 turn (90°) further until after timings have been checked at end of procedure. –  When doing this, hold camshaft chain sprocket with counterhold tool -T10172-. –  Remove locking pin -T10414- from camshaft. –  Unscrew locking pin -T10340- from cylinder block. –  Turn crankshaft 2 revolutions in normal direction of rotation. –  Screw locking pin -T10340- to stop into crankcase. –  Turn crankshaft in normal direction of rotation until the stop. Timing is OK if locking pin -T10414- can be pushed into camshaft. If control times are not OK –  Repeat valve timing adjustment.

–  Turn securing bolt a -1-1/4 turn (90°) further. –  When doing this, hold camshaft chain sprocket with counterhold tool -T10172-. –  Remove locking pin -T10414- and locking pin -T10340-. –  Install valve timing housing (top) → Chapter.

–  Install non-return valve. Specified torque for securing bolt -2-: 8 Nm –  Push on hoses -1-. Only vehicles ► 12.2009 –  Install sump → Chapter. All vehicles

–  Install plug. Specified torque: 30 Nm –  Fill coolant system with coolant → Chapter. Vehicles from production date June 2011 –  If timing chain has been removed and installed or renewed, erase learnt values and adapt engine control unit → Vehicle diagnostic tester„Guided Functions“. Continuation for all vehicles Further assembly is basically the reverse of the dismantling sequence.