Valve Timing, Checking

Special tools and workshop equipment required 

• Torque Wrench (5-50 Nm) V.A.G 1331
• Crankshaft Adapter T03003
• Locking Pin T40069
• Camshaft Clamp T40070

Procedure 

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

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the front section of the right wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Install the crankshaft adapter T03003 onto the vibration damper bolts.

Fig 1: Attaching Wrench T03003 Onto The Vibration Damper Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The crankshaft adapter T03003 can only be installed correctly in one position.

-- Rotate the crankshaft in engine rotation direction until the arrow -A- on the crankshaft adapter T03003 faces downward vertically in comparison to the engine axis. This position corresponds approximately to the crankshaft Top Dead Center (TDC) position.

NOTE:

If the threaded holes in the camshafts -arrows- do not point upward, the crankshaft must be rotated one rotation (360°) in engine rotation direction.

Fig 2: Identifying Camshafts Threaded Holes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the locking bolt -1- from the rear of the cylinder block.

Fig 3: Identifying Locking Pin T40069 And Installing Plug

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Look the through threaded hole and check whether the bore -2- in the crankshaft aligns with the threaded hole.

Use a mirror to do so.

-- If he hole and bore align, install the locking pin T40069 completely into the threaded hole and tighten it to 10 Nm.

If the crankshaft was rotated out past the TDC mark:

-- Rotate the crankshaft back 45° in the opposite direction of engine rotation.

-- Then, rotate the crankshaft again into the TDC position in engine rotation direction.

When the crankshaft is positioned slightly in front of the TDC position (the bore in the crankshaft is 90% visible), the locking pin T40069 can be installed, although slightly more difficult.

NOTE:

With the engine removed, the TDC mark can also be seen on the vibration damper and belt pulley side sealing flange. The notches -A and B- must align.

Fig 4: Aligning Belt Pulley And Sealing Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check whether the crankshaft can be rotated.

The valve timing is correct when the camshaft clamp T40070 bolts can be installed easily into the ends of the camshafts as shown. The support surfaces of the camshaft clamp T40070 must lie flat on the flats of the camshafts when doing this.

Fig 5: Attempting To Rotate Exhaust Camshaft At Recess Using An Open-End Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

If the bolts for the camshaft clamp T40070 can now be installed easily with the chain tensioned in this manner, the valve timing is also correct. Possibly the crankshaft was not secured correctly.

If the camshaft clamp T40070 cannot be installed

The valve timing is incorrect when the camshaft clamp T40070 bolts cannot be installed easily into the ends of the camshafts despite the tensioned chain.

• In this case, the valve timing must be adjusted. Refer to VALVE TIMING, ADJUSTING .

After disassembly and assembly work

-- Remove the locking pin T40069 and install the locking bolt -1- to the rear of the cylinder block.

Fig 6: Identifying Locking Pin T40069 And Installing Plug

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The rest of the installation follows the reverse of the removal procedure.

Tightening Specifications