Contents: Removal ↓ Installation ↓
Adjusting ruler and mandrel for checking the camshaft
Usually, the valve timing adjustment is performed after repairs in which the toothed belt was removed. If the valve timing only needs to be checked, then all work operations are performed without removing the toothed belt.
Removal
1. Remove the upper timing belt cover and cylinder head cover.
2. Mark the direction of rotation of the toothed belt with an arrow drawn on it with a felt-tip pen or grease pencil. The direction of rotation of the engine, when viewed from the front, is to the right, clockwise.
3. Set the crankshaft to the TDC position for cylinder 1.
Caution! In this case, do not under any circumstances rotate the engine by the central bolt of the camshaft gear. For crankshaft rotation, see subsection 2.5.2.1.
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4. The crankshaft is in the TDC position for cylinder 1 if the mark on the flywheel (arrow) matches the corresponding mark on the clutch housing (drawing on the left). At the same time, the cam pair of the first cylinder is directed upwards (drawing on the right).
5. In this position, the 2065 A ruler is installed in the camshaft spline. The ruler can be made independently (see Fig. Adjusting ruler and mandrel for checking the camshaft).
6. Install the ruler into the camshaft spline. The installation ruler (VW-N₂065A) prevents possible camshaft rotation.
7. Balance the alignment ruler parallel to the cylinder head: to do this, turn the crankshaft slightly until one end of the alignment ruler rests on the cylinder head. Measure the resulting gap under the other end of the ruler using a petal feeler gauge. Insert a petal feeler gauge equal to half the measured gap between the alignment ruler and the cylinder head. Rotate the engine until the end of the ruler rests on the feeler gauge. Insert a second petal feeler gauge of the same size under the other end of the ruler – between the ruler and the cylinder head.
8. Now the 2064 mandrel should fit into the hole of the high-pressure fuel pump gear and the pump bracket. The mandrel jams the high-pressure fuel pump gear. You can make the mandrel yourself (see Fig. Adjusting ruler and mandrel for checking the camshaft).
9. If the mandrel does not fit into the hole in the high-pressure fuel pump bracket, the valve timing mechanism must be adjusted again.
10. Loosen the tension roller nut and loosen the timing belt.
11. Loosen the V-belt and remove.
12. Unscrew the vibration damper and the water pump pulley. To do this, engage first gear, apply the handbrake, thereby jamming the crankshaft.
13. Remove the lower timing belt cover.
14. Remove the timing belt.
Attention! The toothed belt must be without breaks. A broken belt must be replaced, because a belt break during operation can lead to serious engine damage.
Caution! If it is necessary to turn the camshaft with the timing belt removed, none of the pistons should be at TDC. Otherwise, serious damage to the pistons or valves is possible.
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15. Before rotating the camshaft, it is necessary to set all pistons to the same height. To do this, make a mark with chalk on the top of the crankshaft belt pulley (prerequisite: the crankshaft is in the TDC position for the cylinder), then turn the crankshaft pulley 1/4 turn (90°) to the right or left. The chalk mark indicates right or left.
Installation
1. Through the hole in the gearbox, check the alignment of the TDC mark on the flywheel with the corresponding mark.
2. Loosen the camshaft gear mounting bolt by 1/2 turn. Knock off the camshaft drive gear by hitting a pin inserted into the 6 mm hole in the rear timing belt cover with a hammer.
3. Put on the timing belt.
4. Tighten the timing belt.
5. Tighten the tension roller nut to 45 Nm.
6. Remove the fuel injection pump gear mandrel.
7. Tighten the camshaft drive gear mounting screw to a torque of 45 Nm.
Attention! If you are going to use an old belt, be sure to observe the direction of movement. Installing the belt in the opposite direction to its movement can lead to belt breakage and engine failure. Therefore, always install the belt so that the arrow indicates the direction of engine rotation (if you look from the front, then clockwise).
8. Remove the installation ruler.
9. Turn the crankshaft 2 revolutions in the direction of engine rotation. Hit the toothed belt between the camshaft drive gear and the fuel injection pump gear with a rubber hammer and check the required toothed belt tension again, tighten if necessary.
10. Check the start of fuel supply from the high-pressure fuel pump (see subsection 2.17.7.6).
11. Install the vibration damper, belt pulley and lower timing belt cover.
12. Install the cylinder head cover gasket, screw on the cylinder head cover. Tighten the nuts to 10 Nm.
13. Install the upper timing belt cover.
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