Valve Timing, Adjusting

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Locking Pins T03006
Multipoint Socket T10035
Counterhold Tool T10172
Camshaft Clamp T40070
2 M8 x 16 Bolts

Modifying the Counterhold Tool T10172

Fig 1: Removing Adapter T10172/1 And Install Bolts

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-- Unscrew the adapter T10172/1 and screw in the 2 M8 x 16 bolts -A-.

NOTE:

The valve timing must be adjusted if the camshaft sprocket or adjuster were loosened during repairs or if the valve timing is not set.

Securing the Camshafts if the Valve Timing is Correct

-- Remove the timing chain cover. Refer to TIMING CHAIN COVER .

-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Secure the crankshaft as described in the "valve timing, checking" procedure. Refer to VALVE TIMING, CHECKING .

-- Install the camshaft clamp T40070 as shown onto the camshafts and tighten the bolts to 20 Nm.

Fig 2: Attempting To Rotate Exhaust Camshaft At Recess Using An Open-End Wrench

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If the bolts are difficult to install, install an 18 or 19 mm open end wrench -A- to the opening on the exhaust camshaft and rotate the camshaft slightly in the -direction of the arrow- to remove any play in the chain.

-- Relieve the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the piston for the chain tensioner and tensioning rail and press the screwdriver in the -direction of arrow-.

Fig 3: Placing Chain Sprockets Into Timing Chain

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-- Secure the completely pressed in piston using the locking pin T03006. the pin must be inserted until it stops.

Securing the Camshafts if the Valve Timing is not Correct

-- Remove the timing chain cover. Refer to TIMING CHAIN COVER .

-- Rotate the crankshaft to Top Dead Center (TDC) for cylinder 5. Refer to CRANKSHAFT, LOCKING . Do not lock the crankshaft using the locking pin T40069.

-- Rotate the crankshaft so that the camshaft clamp T40070 can be installed easily onto the camshafts as shown.

Fig 4: Attempting To Rotate Exhaust Camshaft At Recess Using An Open-End Wrench

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-- Tighten bolts for the camshaft clamp T40070 to 20 Nm.

Remove the Camshaft Sprocket or Adjuster

-- Relieve the tension on the timing chain. To do so, insert a screwdriver of appropriate size between the piston of the chain tensioner and tensioning rail and press the screwdriver in the -direction of the arrow-.

Fig 5: Placing Chain Sprockets Into Timing Chain

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-- Secure the completely pressed in piston using the locking pin T03006. The pin must be inserted until it stops.

-- Remove the bolts -1 and 4- using the multipoint socket T10035 and remove the actuator -2- and the sprocket -3-.

If necessary, the sprocket -3- must be pryed off lightly using a screwdriver.

NOTE:

Lock the crankshaft, refer to CRANKSHAFT, LOCKING if not yet locked. The crankshaft must only be rotated slightly around the TDC point for this. Otherwise there is a risk the valves will rest on the pistons.

Adjusting the Timing

The crankshaft is locked using the locking pin T40069
The camshafts are secured by the camshaft clamp T40070
The chain tensioner is tensioned

-- Place the adjuster -2- and sprocket -3- in the timing chain as illustrated. Position the adjuster and sprocket onto the camshafts and install new bolts -1 and 4- and tighten them by hand.

Fig 6: Placing Chain Sprockets Into Timing Chain

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The adjuster and sprocket must still be able to be rotated, however they must not tilt.

NOTE:

Make sure that timing chain lies correctly in the tensioning and guide rails.

-- Relieve the tension on the chain tensioner by pressing in the piston and pulling out the locking pin T03006.

-- Attach the modified counterhold tool T10172 to the exhaust camshaft sprocket -4-.

Fig 7: Attaching Modified Counterhold Tool Touareg V10 T10172 On To Chain Sprocket For Exhaust Camshaft

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NOTE:

A second technician is needed for the following steps.

-- Hold the timing chain at preload by pressing the counterhold tool T10172 in the -direction of the arrow-.

-- Tighten the bolt -2- for the intake camshaft adjuster and then the bolt -3- for the exhaust camshaft sprocket to 60 Nm.

Then, tighten the bolts -2 and 3- an additional 90° (1/4) turn.

NOTE:

When applying the additional 90° torque angle, the timing chain must no longer be held at preload.

-- Remove the camshaft clamp T40070.

Fig 8: Attempting To Rotate Exhaust Camshaft At Recess Using An Open-End Wrench

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-- Remove the locking pin T40069 for securing the crankshaft.

Fig 9: Identifying Locking Pin T40069 And Installing Plug

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-- Turn the crankshaft 2 turns in engine rotation direction and check the valve timing. Refer to VALVE TIMING, CHECKING .

If the valve timing is not correct:

-- Loosen the intake camshaft adjuster and exhaust camshaft sprocket bolts again and adjust the valve timing again (replace the bolts).

The rest of the installation follows the reverse of the removal procedure. Note the following:

Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt.
Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .