Volkswagen Workshop Service and Repair Manuals

Removing and installing bottom valve timing housing   Note In this engine, the valve timing housing is split. This procedure describes removal and installation of the bottom valve timing housing.

Special tools and workshop equipment required

t	Assembly tool -T10417/1-

t	Torque wrench -VAS 6583-

t	Counterhold tool -3415-

t	Pins -3415/2-

t  Sealant D 176 501 A1 Removing –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Mark the direction of rotation of the poly V-belt and remove belt → Chapter.

–  Lever off dust cap -1- and remove idler roller. –  Remove coolant pump pulley. –  Hold pulley with water pump wrench -V.A.G 1590-.

–  Loosen pulley securing bolt. Hold pulley with counterhold tools -3415- and -3415/2-. –  Remove sump → Chapter.

–  Loosen all securing bolts of valve timing housing -1-. –  Remove valve timing housing. Installing   Note t  The installation procedure must not be allowed to exceed 6 minutes from the moment when the sealant is applied to the point when the securing bolts are tightened to 5 Nm + 30° further. t  The sealant starts to harden after 6 minutes. t  Use new securing bolts. –  Clean sealing surfaces carefully. They must be free of oil and grease.

–  Apply sealant D 176 501 A1 -1- to sealing surface. Bead of sealant must be 2 … 3 mm thick and must run around holes in area of bolt holes.

–  Push assembly tool -T10417/1- onto crankshaft journal. –  Carefully push valve timing housing -1- and seal over assembly tool. –  Remove assembly tool from crankshaft journal.

–  Push valve timing housing onto dowel pins -arrows- as far as stop on cylinder block. Ensure that timing housing is not canted.   Caution Note torque setting of securing bolts! Use new bolts when installing. –  First of all, tighten new securing bolts of valve timing housing evenly until finger-tight.

–  Tighten securing bolts in sequence as specified -A- to -M- using torque wrench -VAS 6583-. Torque setting of valve timing housing securing bolts: 5 Nm + 30° further Installing crankshaft pulley → Chapter. Specified torques Pulley for coolant pump: 20 Nm Idler roller: 40 Nm Further assembly is basically the reverse of the dismantling sequence.