Engine assembly (VW Tiguan 1)

Poly V-belt reeving

Caution: Before installing the poly V-belt, check that all components driven by it are securely fastened (generator, air conditioning compressor). When installing the poly V-belt, pay attention to the direction of travel and the correct fit on the pulleys and tension elements. First, place the poly V-belt on the crankshaft pulley. Lastly, tighten the belt on the tension roller. Further installation and assembly is carried out in the reverse order of removal. Fill with coolant. Upon completion of work, it is mandatory to. Start the engine and check the movement of the drive belt.

Belt drive with air conditioning compressor

• 1 - Belt pulley - coolant pump
• 2 - Belt pulley - crankshaft
• 3 - Tension roller
• 4 - Tension roller
• 5 - Belt pulley - generator
• 6 - Belt pulley - air conditioning compressor
• 7 - Poly V-belt

Belt drive compressor

Instruction: The belt pulley of the electromagnetic clutch of the compressor "N421" is located behind the belt pulley - the pump of the cooling system. The poly V-belt "4" passes through the belt pulley of the electromagnetic clutch of the compressor "N421".

• 1 - Belt pulley - compressor
• 2 - Tension roller
• 3 - Belt pulley of the cooling system pump with belt pulley of the electromagnetic clutch of the compressor "N421"
• 4 - Poly V-belt

Removal and installation the sealing flange and flywheel/driven disk

• 1 - Fastening screw, replace. The contact surface of the bolt head must be free of oil and grease, insert after lubricating with oil (thread). Secure the belt pulley from turning with counter support 3415, the tightening angle can be measured with a standard measuring disc, e.g. Hazet 6690
• 2 - Belt pulley. There should be no oil or grease on the mating surfaces; when removing or installing, secure with key 3415 against rotation
• 3 - Lip seal, replace
• 4 - Bearing bush. There should be no oil or grease on the mating surfaces
• 5 - O-ring, replace
• 6 - Cylinder block
• 7 - 60 Nm and turn 90° further
• 8 - Flywheel/driven disk. To remove or install, secure the flywheel with the "T10044" locking key
• 9 - Intermediate plate, must sit on the mounting bushings, not be damaged/bent during installation work
• 10 - 12 Nm, replace
• 11 - Sealing flange with sensor wheel and lip seal. Tightening torque of engine speed sensor "G28": 5 Nm. Replace the sealing flange only as a complete assembly with lip seal and wheel

Cylinder head

Instructions: When installing a new cylinder head, before assembling the camshaft housing, lubricate all contact surfaces between the bearing elements, roller levers and camshaft bed with engine oil. The plastic linings included in the repair kit for protecting open valves may only be removed immediately before installing the cylinder head. When replacing the cylinder head, you should also drain the old coolant and fill it with new coolant. All seating and working surfaces must be lubricated before installation.

• 1 - 8 Nm
• 2 - High pressure pump for the fuel system, with fuel pressure regulating valve "N₂76"
• 3 - Wiring box, screw to camshaft housing with a torque of 8 Nm
• 4 - To the air filter
• 5 - 10 Nm
• 6 - Hall sensor "G40", with a lip seal. If the sealing ring is damaged, replace it
• 7 - Expansion bolt, 6 Nm
• 8 - 10 Nm and turn 90°, replace, tighten from the center to the edges
• 9 - Camshaft housing, remove the remains of the old sealant, carefully clean the seating surfaces; they must be free of oil and grease, lubricate with D 188 003 A1 before installation. When installing, place vertically from above on the expansion bolt and mounting pins
• 10 - 20 Nm
• 11 - Hanging eye
• 12 - Turbocharger
• 13 - Oil pressure sensor "F1", 25 Nm. If not tight, bite and replace the lip seal
• 14 - Cylinder head gasket, replace, metal gasket. After replacement, change the coolant
• 15 - Cylinder head, there should be no oil or grease on the seating surface, change the coolant after replacement
• 16 - Guide bolt, 20 Nm
• 17 - Dowel pin
• 18 - Support element, do not change places, with hydraulic compensator, lubricate the working surface with oil
• 19 - Roller lever, check the roller bearings for ease of rotation, lubricate the working surface with oil. For installation, clip it to the support element using the fixing bracket
• 20 - Sealing ring. When removing and installing the camshaft bearing housing, it is necessary to take into account the various seals, replace, 4 pcs., used in the cylinder head
• 21 - Cylinder head mounting bolt, replace. Follow installation instructions and sequence when loosening and tightening
• 22 - Roller tappet. Lightly lubricate the working surfaces with engine oil
• 23 - O-ring, replace, moisten with engine oil before replacing

Checking the cylinder head for warpage

Maximum permissible curvature of the mating plane: 0.05 mm.

Adjusting the valve timing

Remove the timing cover. To rotate the crankshaft, insert the support sleeve, crankshaft belt pulley "2" and crankshaft bolt "3", then screw in the bolt (use counter support 3415).



Remove the spark plug of the first cylinder. To do this, use the puller -T10094 A- and spark plug wrench 3122 B. Screw the adapter for the dial indicator "T10170" into the spark plug socket until it stops. Insert the dial indicator -VAS 6079- with the extension -T10170/1- until it stops and press it with the "arrow" nut.



Turn the crankshaft in the direction of engine rotation to TDC of cylinder 1. Remember the position of the small arrow of the dial indicator. Then turn the crankshaft against the direction of engine rotation back by 45°. Press the tensioner bar "1" in the direction of the arrow and fix the piston with the locking pin "T40011". Mark the direction of the timing chain movement with a felt-tip pen "3".

Instructions: The central bolt of the phase shifter "2" has a left-hand thread.

Unscrew bolts "2" and "4" and remove phase shifter "1" with timing chain "3". Use counter support "T10172" to hold. Reinstall phase shifter "1". Replace bolts "2" and "4" and tighten bolt "2" to 40 Nm, and bolt "4" to 50 Nm (use counter support -T10172-).



Turn the inlet and outlet camshafts until the camshaft locking tool -T10171 A- fits into the holes in the camshafts as far as it will go. The locking pins "arrows 1" must fit into the holes "arrows 2". The "TOP" mark "arrow 3" must be visible from above.

Instructions: When cranking, the camshafts must not be moved along the axis.

To attach the camshaft lock -T10171 A- screw the M6 bolt into the corresponding hole "arrow" by hand; don't delay.

Instructions: It is necessary to take into account that there are different attachment points for the camshaft locking device "TYu171A".

Unscrew the bolts of the camshaft sprockets. To do this, be sure to use the counter support-T10172-.

Instructions: Do not use the camshaft locking tool -T10171 A- as a counter wrench.

Remove one camshaft sprocket. Place the timing chain, observing the direction of travel, on the camshaft sprockets and put the removed sprocket back on. Screw in the camshaft bolts so that the sprockets still turn on the camshafts. Tighten the timing chain by pulling out the locking pin "T40011". Turn the crankshaft in the direction of engine rotation to TDC of cylinder 1. Permissible deviation from TDC of cylinder 1: ±0.01 mm.

Instructions: If the crankshaft has been turned further than TDC by more than 0.01 mm, it should be turned again against the direction of engine rotation by approximately 45°. Finally, bring the crankshaft in the direction of engine rotation to TDC of cylinder 1.

Unscrew the "arrow" plug in the engine crankcase.



Screw the "T10340" locking bolt into the engine crankcase until it stops. Tighten the "T10340" locking bolt with a tightening torque of 30 Nm. The "T10340" locking bolt locks the crankshaft in the direction of engine rotation.



Hold the camshaft sprockets "1" and "5" in this position using the counter support "T10172" and tighten the bolts "2" (left hand thread) with a tightening torque of 40 Nm and "4" at 50 Nm.

Instructions: When tightening the camshaft bolts, the crankshaft should not turn, and the timing chain "3" should remain taut on both sides.

Remove the camshaft locking tool -T10171 A-. Unscrew the locking bolt "T10340" from the engine crankcase. Turn the crankshaft in the direction of engine rotation by two turns to TDC of cylinder 1. Permissible deviation from TDC of cylinder 1: ±0.01 mm. Insert the camshaft locking tool -T10171 A- into the holes in the camshafts until it stops. If the camshaft locking tool -T10171 A- does not fit. Repeat the adjustment. If the camshaft locking tool -T10171 A- fits. Screw the locking bolt "T10340" into the engine crankcase until it stops. Tighten the locking bolt "T10340" to a tightening torque of 30 Nm. Remove the camshaft locking tool -T10171 A-, firmly hold the camshaft sprockets with the counter support "T10172", and tighten the bolts "2" (left hand thread) and "4" with a 1/4 vol. hard wrench.

Instructions: The central bolt of the phase shifter "2" has a left-hand thread. The sprockets should not rotate on the camshafts when tightening the bolts.

Further installation and assembly is performed in the reverse order of removal. In this case, the following must be taken into account.

[The original information is posted on the resource VWMANUAL.ru]

Instructions: The "T10340" locking bolt remains in the engine crankcase until the crankshaft belt pulley is installed.

Installing the regulator housing. Installing the crankshaft belt pulley. Installing the poly V-belt. Replacing the camshaft plug seals and lubricate them with oil before installation.