Setting the Timing
Setting the timingTools
Preliminary work
1. Timing checked
2. Remove engine.
3. Remove cylinder head cover.
TDC Of Cylinder 1:
4. Position crankshaft to the TDC of cylinder 1.
5. Remove top and bottom chain case lid.
Information
Component information
Overview Of Timing Drive Mechanism:
Tools and materials
Note: The tools can be purchased from the VW Parts Service.
Note: Observe the most important working regulations and warning notes --> 'The most important working regulations and warning notes'.
Special Tool:
Setting the timing
ATTENTION: Engine damage due to turning the crankshaft against the running direction (engine assembled)!
--> Never turn the engine against the running direction when the timing drive mechanism is fitted (timing chain may jump over).
--> Proceed carefully while working as otherwise engine damage may occur.
--> Only turn the engine on the crankshaft and never on the camshaft as the timing chain can jump over.
--> After working on the camshaft timing gears, the timing must be adjusted.
--> Please observe the general warning notes and working regulations --> '10 The most important working regulations and warning notes'
Note:
^ To set the timing, the engine must be removed and the transmission disconnected because it is likely that more extensive diagnostic work is necessary on the timing drive mechanism!
^ The timing must be set following extensive disassembly work relating to engine control (e.g. cylinder head removal and installation).
^ The timing for this engine does not go wrong for no reason because safety mechanisms (e.g. pins or chamfered areas) are installed in the entire timing drive mechanism, which prevent the timing from going wrong.
^ If the timing is incorrect, the engine must be checked for mechanical damage in order to determine the cause and extent of damage.
Note:
^ Check all components, such as timing chains, sprockets, locking pins and chamfers for wear or damage. Replace faulty components.
^ Always replace all fastening screws for the sprockets.
Timing Chain Markings:
^ Before removal, mark the timing chain rolling direction and timing chains with a colored pen --> Timing chain markings. Retain timing chain running direction and timing chains during re-installation. Never use a prick punch or file for marking.
Arm Bracket Blocking Crankshaft:
1. Block crankshaft using an arm bracket T10069 with the help of an assistant.
Overview Of Timing Drive Mechanism:
2. Undo fastening screw on intermediate shaft -14-.
3. Remove timing chain -3- between intermediate shaft and camshafts. To do this, remove black guide rail -24- by loosening the two M8 x 43 fastening screws -21- and remove timing chain up to camshaft.
Note:
^ The chain tensioner between the crankshaft and intermediate shaft is spring-tensioned.
Chain Tensioner:
^ The chain tensioner between the crankshaft and intermediate shaft can be reset. To do this, unblock the locking teeth in the side bore of the chain tensioner -A- using a small screwdriver and press the tensioning rail against the chain tensioner.
4. Remove chain tensioner for timing chain between crankshaft and intermediate shaft. To do this, loosen two fastening screws (M6 x 24) and remove chain tensioner with tensioning rail attached.
5. Remove timing chain with intermediate shaft sprocket.
Crankshaft Pulley Marking To Cylinder Block:
Worn Drive Gear Tool -B- To Bearing Joint Face (Shown With Top Timing Chain Fitted):
6. Check that the crankshaft is now positioned in the TDC of cylinder 1. To do this, align the crankshaft marking with the marking on the cylinder block --> Crankshaft pulley marking to cylinder block --> Worn drive gear tooth -B- to bearing joint face (shown with top timing chain fitted).
7. Position intermediate shaft so that the sprocket markings -C and D- correspond to the lines on the underlying thrust washer.
Markings:
Note: Install bottom timing chain in running direction (marking) -arrows-.
Bottom Timing Chain:
8. Position bottom timing chain with chain sprocket -4-. To do this, position the timing chain around the crankshaft drive gear and intermediate shaft sprocket in such a way that the timing chain runs straight through the guide rail -2- without play. Leave the side of the timing chain leading to the chain tensioner -A- loose.
9. Place sprocket -3- on the intermediate shaft gearwheel -4- and install hand-tight using a new fastening screw (M12 x 40).
Note: Unblock the locking teeth in the chain tensioner with a small screwdriver and press tensioning rail against the chain tensioner.
10. Move tensioned chain tensioner into installation position and fit using two fastening screws. Tightening torque 6.0 ft. lbs..
Arm Bracket Blocking Crankshaft:
11. Block crankshaft using an arm bracket T10069 with the help of an assistant.
Timing Drive Mechanism:
12. Tighten fastening screw for intermediate shaft -14-. Tightening torque 44 ft. lbs.. Torque angle 90°
Camshaft Hexagon:
Camshaft Guide In Grooves Of Camshaft -A-:
13. Turn both camshafts at the hexagon -arrow- in such a way that the camshaft guide T10068 -A- fits into the grooves of both camshafts.
Overview Of Timing Drive Mechanism:
14. Slide tensioning rail -8- on to the collarless bolt -9-.
Markings:
Note: Install top timing chain in running direction (marking) -arrows-.
Note: The timing chain has two copper-colored and one yellow chain link. These must match the corresponding markings on the chain sprockets or camshaft adjusters. The markings on the components are definitive for setting the timing so that the timing can also be set without the colored chain links. The colored chain links serve only as support.
Camshaft Adjuster And Tensioning Rail:
View From Above:
15. Lay timing chain between camshafts and intermediate shaft. The yellow chain link must correspond to the marking on the intermediate shaft sprocket -2-. Guide the timing chain along the black guide rail and fit to the camshaft adjusters. Make sure that the copper-colored chain links correspond to the engraved arrows on the camshaft adjusters -1-. Guide the top timing chain at the guide rail side (shown fitted here) without play. Only leave the timing chain loose at the tensioning rail side -3- (chain tensioner side).
Markings:
16. Check position of camshaft adjusters. The engraved arrows -A and B- on the camshaft adjusters must be aligned with the notches -arrows- on the timing chain housing -C- and the copper-colored chain links. The distance between tooth -1- and tooth -2- of the camshaft adjusters must be exactly 16 rolls of the camshaft chain tensioner.
Guide Rail:
17. Slide the black guide rail -1- on to the collarless bolt and fold on to the timing chain. Tighten the two fastening screws -arrows-. Tightening torque 17 ft. lbs..
Tensioning Rail:
18. Make sure that the timing chain is only loose at the tensioning rail side -3-.
19. Remove camshaft guide.
Note:
^ If the colored chain links are used for setting the timing, these will no longer be in the same position after you have turned the crankshaft to check it out and then checked the timing again.
^ Only the markings on the components are definitive.
20. Press the tensioning rail by hand or with a light tap of a hammer on to the timing chain instead of the removed chain tensioner and get an assistant to help turn the crankshaft by four turns. Check the timing.
Subsequent work
1. Install bottom chain case lid.
2. Install top chain case lid.
3. Check the timing using a standard chain tensioner.
4. Install cylinder head cover.
5. Install engine.