Volkswagen 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive). Manual (Edition 08.2018) - page 4

– Install inlet camshaft control valve 1 - N205-

Install in reverse order of removal, observing the following.
– Lubricate seal and O-ring with engine oil.

1.3

Removing and installing upper timing

chain cover

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

♦ Open-end spanner insert AF 10 - V.A.G 1783/1-
Removing
– Remove engine cover panel

⇒ page 141

– Only vehicles with sound generator: Open catch -1-, unclip fuel

lines -2- and loosen bolt -3- on activated charcoal filter. Place

charge air pipe to one side.

Vehicles with activated charcoal filter in engine compartment:

– Pull off breather line -1-, release activated charcoal filter -A-

and remove upwards -B-. Place activated charcoal filter to one

side.

All:

– Unscrew coolant pipe bolts -arrows- from intake manifold.
– Push coolant hoses to one side and secure on engine mount‐

ing using cable ties.

– Removing inlet camshaft control valve 1 - N205- .

– Unscrew bolts -1…5- and remove upper timing chain cover.

Note

Unscrew lower bolts -3- and -5- using an open-end spanner.

Installing:
– Lubricate gasket and O-ring with engine oil.
– Position cover on engine, ensuring that gasket is correctly

seated.

– Hand-tighten bolts -1 to 5- evenly in the sequence shown:
– Further tighten bolts to 9 Nm. Use torque wrench - V.A.G 1783-

and open end spanner insert AF10 - V.A.G 1783/1- for bolts

-3- and -5-.

⇒ page 91

Rep. gr.15 - Cylinder head, valve gear

– Tighten bolts -arrows- for guide tube.

Note

If the mounting holes don't align, check if the guide tube has been

inserted to stop into the lower timing chain cover.

• Specified torques

Further assembly is basically a reverse of the dismantling se‐

quence.

1.4

Removing and installing lower timing

chain cover (Passat, CC)

Special tools and workshop equipment required
♦ Locking pin - T10060 A-

♦ Counter-hold tool - T10355-

♦ Assembly tool - T10531-

♦ Bits - T10099-

♦ Support - 10 - 222 A-

♦ Passat 2006▶: Rack - 10 - 222 A /1-

♦ CC: Adapter - 10 - 222 A /8-

♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)
Removing
– Remove vibration damper

– Drain engine oil.
– Support engine in installation position.

Rep. gr.15 - Cylinder head, valve gear

Passat 2006▶:
♦ Rack - 10 - 222 A /1-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-

CC:
♦ Adapter - 10 - 222 A /8-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-

Note

♦

The adapters - 10 - 222 A /8- must not be located on the screw

plates of the wings, as this will otherwise cause damage to

them.

♦

The shackle - 10 - 222 A /12- is needed so the engine is raised

in its installation position and does not »fall back«.

All:
– Take up weight of engine with spindle.

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

gine.

– Removing engine mounting

⇒ page 21

– Raise engine approx. 50 mm and loosen upper engine support

bolt.

– Now lower engine approx. 100 mm.

– Move electrical wiring harness clear -arrow-.
– Remove bolt -1- and take off tensioning device for poly V-belt

from bracket for ancillaries.

– Unscrew lower bolts for engine support using bits - T10099- .
– Remove engine support with bolts.

– Remove bolts -arrows- and pull guide tube for oil dipstick out

of timing chain cover.

– Remove charge pressure solenoid valve - N75- from turbo‐

charger -arrows-.

– Remove turbocharger connection -1-.

– Unscrew bolts -1 … 15-.

Note

Depending on version, the cover may be secured with only 8

bolts.

Caution

Risk of damaging lower timing chain cover. To prevent dam‐

aging the timing chain cover, apply tool only at the bolt holes.

Rep. gr.15 - Cylinder head, valve gear

– Lever off lower timing chain cover, starting at points

-1 and 2-.

Installing
♦ Specified torques

Note

♦

If the cover was bent during removal, it must be renewed.

♦

Note expiry date of silicone sealant.

♦

The cover must be installed within 5 minutes after applying the

silicone sealant.

♦

Renew bolts which must be tightened further to a torque angle.

♦

Renew seals, gaskets and self-locking nuts.

Caution

♦ Danger of contaminating lubrication system! Cover open

parts of engine.

♦ Wear protective goggles.

– Remove sealant residues from cylinder block with a flat scra‐

per.

– Mask oil seal on both sides with adhesive tape to make sure

seal remains clean.

– Remove remaining sealant from cover, e.g. using rotating

plastic brush.

– Clean sealing surfaces. They must be oil and grease free.
Checking cover for distortion:
– Fit cover using old bolts and tighten to 8 Nm.
– Use feeler gauge to measure distance between cover and

housing (max. distance is 0.2 mm).

Note

♦

Renew cover if distance exceeds 0.2 mm.

♦

It is not possible to measure distance between cover and sump

(top section); check visually to ensure that sealing surface is

even.

Installing cover:
– If necessary, unscrew flange nut - T10531/4- , and remove

turning over tool - T10531/3- .

– Check that both dowel pins for centring the cover -arrows- are

fitted.

– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2

mm).

Cover with 15 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

to edges -arrows 2- of new cover as shown in illustration.

♦ Thickness of sealant bead: 2 to 3 mm.

Rep. gr.15 - Cylinder head, valve gear

Cover with 8 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

to edges -arrows 2- of new cover as shown in illustration.

♦ Thickness of sealant bead: 2 to 3 mm.

Note

♦

The cover must be installed within 5 minutes after applying the

silicone sealant.

♦

The bead of sealant must not be thicker than specified, other‐

wise excess sealant can enter the sump and obstruct the

strainer in the oil intake pipe.

– Install cover immediately and tighten bolts:
♦ Cover, version with 15 bolts

♦ Cover, version with 8 bolts

– Install vibration damper

Further assembly is basically a reverse of the dismantling se‐

quence.

Note

After fitting cover, let sealant dry for approx. 30 minutes. Only then

fill with engine oil.

– Replenish engine oil and check oil level.

1.5

Removing and installing lower timing chain cover (Golf, Eos, Scirocco)

♦ Assembly tool - T10531-

♦ Eos, Scirocco: Rack - 10 - 222 A /1-

Removing
– Remove vibration damper

– Drain engine oil.
Vehicles with sound generator:
– Remove charge air duct to sound generator

⇒ page 455

All:
– Fit support bracket - 10 - 222 A- with the following tool parts:
Golf:
♦ Adapter - 10 - 222 A /13- , qty. 2
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-

101

Eos, Scirocco:
♦ Rack - 10 - 222 A /1-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-

Note

♦

The rack feet - 10 - 222 A /1- must not be placed on the bolted

on sheet metal of the wings, or these might be damaged.

♦

The shackle - 10 - 222 A /12- is needed so the engine is raised

in its installation position and does not »fall back«.

All:
– Take up weight of engine with spindle.

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

gine.

– Removing engine mounting

⇒ page 21

– Raise engine approx. 50 mm and loosen upper engine support

bolt.

– Now lower engine approx. 100 mm.

– Move electrical wiring harness clear -arrow-.
– Remove bolt -1- and take off tensioning device for poly V-belt

from bracket for ancillaries.

– Unscrew lower bolts for engine support using bits - T10099- .
– Remove engine support with bolts.

– Remove bolts -arrows- and pull guide tube for oil dipstick out

of timing chain cover.

Rep. gr.15 - Cylinder head, valve gear

– Remove charge pressure solenoid valve - N75- from turbo‐

charger -arrows-.

– Remove turbocharger connection -1-.

– Unscrew bolts -1 … 15-.

Note

Depending on version, the cover may be secured with only 8

bolts.

Caution

Risk of damaging lower timing chain cover. To prevent dam‐

aging the timing chain cover, apply tool only at the bolt holes.

103

– Lever off lower timing chain cover, starting at points

-1 and 2-.

Installing:
♦ Specified torques

Note

♦

If the cover was bent during removal, it must be renewed.

♦

Note expiry date of silicone sealant.

♦

The cover must be installed within 5 minutes after applying the

silicone sealant.

♦

Renew bolts which must be tightened further to a torque angle.

♦

Renew seals, gaskets and self-locking nuts.

Caution

♦ Danger of contaminating lubrication system! Cover open

parts of engine.

♦ Wear protective goggles.

– Remove sealant residues from cylinder block with a flat scra‐

per.

– Mask oil seal on both sides with adhesive tape to make sure

seal remains clean.

– Remove remaining sealant from cover, e.g. using rotating

plastic brush.

housing (max. distance is 0.2 mm).

Note

♦

Renew cover if distance exceeds 0.2 mm.

♦

It is not possible to measure distance between cover and sump

(top section); check visually to ensure that sealing surface is

even.

Rep. gr.15 - Cylinder head, valve gear

Installing cover:
– If necessary, unscrew flange nut - T10531/4- , and remove

turning over tool - T10531/3- .

– Check that both dowel pins for centring the cover -arrows- are

fitted.

– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2

mm).

Cover with 15 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

to edges -arrows 2- of new cover as shown in illustration.

♦ Thickness of sealant bead: 2 to 3 mm.

105

Cover with 8 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

to edges -arrows 2- of new cover as shown in illustration.

♦ Thickness of sealant bead: 2 to 3 mm.

Note

♦

The cover must be installed within 5 minutes after applying the

silicone sealant.

♦

The bead of sealant must not be thicker than specified, other‐

wise excess sealant can enter the sump and obstruct the

strainer in the oil intake pipe.

– Install cover immediately and tighten bolts:
♦ Cover, version with 15 bolts

♦ Cover, version with 8 bolts

– Install vibration damper

Further assembly is basically a reverse of the dismantling se‐

quence.

Note

After fitting cover, let sealant dry for approx. 30 minutes. Only then

fill with engine oil.

– Replenish engine oil and check oil level.

1.6

Removing and installing bottom timing

chain cover (Tiguan)

Special tools and workshop equipment required
♦ Support - 10-222A-

♦ Shackle - 10-222A/12-
♦ Adapter - 10-222A/16-
♦ Adapter - 10-222A/18-
♦ Adapter - 10-222A/22-
♦ Adapter - 10-222A/19-

Rep. gr.15 - Cylinder head, valve gear

♦ Bits - T10099-

♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)
Removing
– Remove vibration damper

– Drain engine oil.
– Remove engine cover panel

⇒ page 141

– Fit support bracket - 10 - 222 A- as shown. The rear spindle is

not required. Attach hooks to support eyes on engine and

support engine and gearbox.

– Take up weight of engine with spindle.

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

gine.

– Removing engine mounting

⇒ page 23

– Raise engine approx. 50 mm and loosen upper engine support

bolt.

– Now lower engine approx. 100 mm.

Rep. gr.15 - Cylinder head, valve gear

– Move electrical wiring harness clear -arrow-.
– Remove bolt -1- and take off tensioning device for poly V-belt

from bracket for ancillaries.

– Unscrew lower bolts for engine support using bit - T10099- .
– Remove engine support with bolts.

– Remove bolts -arrows- and pull guide tube for oil dipstick out

of timing chain cover.

– Remove charge pressure solenoid valve - N75- from turbo‐

charger -arrows-.

– Remove turbocharger connection -1-.

– Unscrew bolts -1 … 15-.

Note

Depending on version, the cover may be secured with only 8

bolts.

Caution

Risk of damaging lower timing chain cover. To prevent dam‐

aging the timing chain cover, apply tool only at the bolt holes.

109

– Lever off lower timing chain cover, starting at points

-1 and 2-.

Installing:
♦ Specified torques

Note

♦

If the cover was bent during removal, it must be renewed.

♦

Note expiry date of silicone sealant.

♦

The cover must be installed within 5 minutes after applying the

silicone sealant.

♦

Renew bolts which must be tightened further to a torque angle.

♦

Renew seals, gaskets and self-locking nuts.

Caution

♦ Danger of contaminating lubrication system! Cover open

parts of engine.

♦ Wear protective goggles.

– Remove sealant residues from cylinder block with a flat scra‐

per.

– Mask oil seal on both sides with adhesive tape to make sure

seal remains clean.

– Remove remaining sealant from cover, e.g. using rotating

plastic brush.

housing (max. distance is 0.2 mm).

Note

♦

Renew cover if distance exceeds 0.2 mm.

♦

It is not possible to measure distance between cover and sump

(top section); check visually to ensure that sealing surface is

even.

Rep. gr.15 - Cylinder head, valve gear

Installing cover:
– If necessary, unscrew flange nut - T10531/4- , and remove

turning over tool - T10531/3- .

– Check that both dowel pins for centring the cover -arrows- are

fitted.

– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2

mm).

Cover with 15 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

to edges -arrows 2- of new cover as shown in illustration.

♦ Thickness of sealant bead: 2 to 3 mm.

111

Cover with 8 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

to edges -arrows 2- of new cover as shown in illustration.

♦ Thickness of sealant bead: 2 to 3 mm.

Note

♦

The cover must be installed within 5 minutes after applying the

silicone sealant.

♦

The bead of sealant must not be thicker than specified, other‐

wise excess sealant can enter the sump and obstruct the

strainer in the oil intake pipe.

– Install cover immediately and tighten bolts:
♦ Cover, version with 15 bolts

♦ Cover, version with 8 bolts

– Install vibration damper

Further assembly is basically a reverse of the dismantling se‐

quence.

Note

After fitting cover, let sealant dry for approx. 30 minutes. Only then

fill with engine oil.

– Replenish engine oil and check oil level.

1.7

Camshaft timing chain - exploded view

Rep. gr.15 - Cylinder head, valve gear

1 - Bolt

❑ 9 Nm

2 - Chain tensioner

❑ Is spring-loaded
❑ Depending on version,

secure with locking pin -

T40011- or locking tool -

T40267- .

3 - Tensioning rail for timing

chain
4 - Guide pin

❑ 20 Nm

5 - Bolt

❑ 9 Nm

6 - Timing valve

❑ Left-hand thread
❑ Checking

⇒ page 114

❑ Remove with assembly

tool - T10352-

❑ Engine codes CCZA,

CCZB, CCZC, CCZD,

CDAA, CDAB: use as‐

sembly tool - T10352/1-

to remove

❑ 35 Nm

7 - Bolt

❑ Renew
❑ M6: 8 Nm + 90° further
❑ M8: 20 Nm + 90° further

8 - Washer
9 - Bearing saddle
10 - Guide rail for camshaft timing chain
11 - Camshaft case
12 - Camshaft timing chain

❑ Before removing, mark running direction with paint
❑ Removing and installing

⇒ page 114

13 - Guide rail for camshaft timing chain
14 - Guide pin

❑ 20 Nm

15 - Sprocket

❑ Crankshaft
❑ Fitting position

⇒ page 114

113

♦ Assembly tool - T10531-

Components of assembly tool - T10531- :
♦ Support - T10531/1-
♦ Clamping pin - T10531/2-
♦ Turning over tool - T10531/3-
♦ Flange nut - T10531/4-
Removing:
– Remove timing chain cover (top)

⇒ page 91

– Turn vibration damper to “TDC” position -arrow- using coun‐

terhold - T10355- .

• Notch on vibration damper must align with arrow marking on

cover for timing chains (bottom).

• The markings -1- on the camshafts must face upwards.
– Remove vibration damper