Installing (Adjusting Valve Timing): Notes

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: There are different tensioning rollers -A or B- installed.

Fig 1: Identifying Tensioning Rollers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The distinguishing characteristic is the adjustment eccentric -1-.

For tensioning roller -A- the drift with the Tensioning Roller Locking Tool T10265 is discontinued.

To tension the Wrench - Hex - 8 mm T10409 must be used.

The procedure is otherwise identical.

NOTE: The engine must be cold when adjusting the toothed belt.

CAUTION: Risk of damaging valves and piston crowns.

If camshafts are being rotated, crankshaft may not rest with any piston at "TDC".

Requirements:

Fig 2: Identifying Wrench - Tensioning Roller T10264 And Tensioning Roller Locking Tool T10265

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The tensioning roller -B- must be secured with the Tensioning Roller Locking Tool T10265 and fasted to the right stop with the nut -1-.

The metal tab -arrow- on the tensioning roller must fit into the cast depression in the cylinder head.

Fig 3: Identifying Metal Tab
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Secure the camshaft hub with the Diesel Injection Pump Locking Pin 3359.

Fig 4: Identifying Diesel Injection Pump Locking Pin
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Bolt loosely installed.
It must still be easily possible to rotate the camshaft toothed belt gear and it must not tip.

Loosen the carrier bolt -1- half a turn in the center position in the oblong hole -2-.

Fig 5: Identifying Crankshaft Holder
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The crankshaft must be secured with the Crankshaft Lock T10490.

Fig 6: Identifying Crankshaft Lock T10490
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Secure the hub on the high pressure pump with the Locking Pin T10492.

Fig 7: Identifying Locking Pin
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Nut loosely installed.
It must still be easily possible to rotate the high pressure pump toothed belt gear and it must not tip.

-- Turn the camshaft toothed belt gear and the high pressure pump toothed belt gear all the way clockwise by the oblong holes.

Fig 8: Identifying Crankshafts, Tensioning Roller, Camshaft Toothed Belt Gear, Toothed Belt Sprocket For High Pressure Pump And Coolant Pump Toothed Belt Gear

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mount the toothed belt in the following sequence:

Crankshafts - toothed belt gear
Tensioning roller
Camshaft Toothed Belt Gear
High Pressure Pump Toothed Belt Sprocket
Coolant pump toothed belt gear

-- Loosen the nut -1- on the tensioning roller -B- and remove the Tensioning Roller Locking Tool T10265.

Fig 9: Identifying Wrench - Tensioning Roller T10264 And Tensioning Roller Locking Tool T10265

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Tensioning roller metal tab must fit into the cast depression in the cylinder head.

Ignore -arrow-.

CAUTION: The crankshaft holder must not come into contact with the oblong hole upper stop after tensioning the toothed belt.

-- Check if the crankshaft holder -1- is between the center oblong hole and the lower stop -2-. If necessary adjust the position of the camshaft sprocket one tooth clockwise and install the toothed belt again.

Fig 10: Identifying Crankshaft Holder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully turn the tensioning roller eccentric pulley clockwise -arrow- with the Wrench - Tensioning Roller T10264 or the Wrench - Hex - 8 mm T10409 until the indicator is located centrally in the gap of the base plate -2-.

Fig 11: Identifying Wrench - Tensioning Roller T10264

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The nut -1- must not turn with it.

-- Hold the tensioning roller in this position and tighten the nut.

-- Position the Counterhold - Kit - Multiple Use T10172 on the camshaft toothed belt sprocket with the Camshaft Lock T10172/11 as shown.

Fig 12: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the counterholder counter-clockwise in direction of -arrow- and hold at pre-load.

-- Tighten the bolts -1- for the camshaft toothed belt gear and the nuts -2- for the high pressure pump toothed belt gear to 10 Nm in this position.

NOTE: The high pressure pump toothed belt sprocket has a limited range of motion. It must be checked that the toothed belt gear after tensioning does not contact the range of motion >>stop<<.

-- Make sure that the high pressure pump toothed belt sprocket is not aligned with the locking pin. If necessary adjust the position of the camshaft sprocket one tooth clockwise and install the toothed belt again.

Fig 13: Identifying Locking Pin T10492

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the Diesel Injection Pump Locking Pin 3359, T10492 and Crankshaft Lock T10490 and check the valve timing, refer to Checking the Valve Timing .