VAG TIMING TOOL KIT – 1.8/2.0 4v TFSi & 2.0L TURBO TIMING SET

Introduction:
The kit consists of 11 main components which
include the tools recommended by the
manufacturer to set No.1 cylinder at TDC. It is
important that the correct process is followed
when setting up these engines.

VAG TIMING TOOL KIT
VAG TIMING TOOL KIT
Image 12
2.0L Turbo Timing Set Applicable to VAG vehicles with a 2.0L (turbo) engine
T10355: Used for counter-holding the vibration damper when loosening
or tightening the center bolt of the Crankshaft
T10368: Used when removing and installing Lower Timing Chain Cover
T40196: Used for sliding pieces on Camshaft on 2.0L 4V Turbo engines

Instruction:
Preparation and Precautions:
Raise the front of the vehicle and remove the front
wheels and inner wheel arches as required.
Remove the engine under shield, top cover, air
intake, auxiliary drive belt(s).
Ensure the engine is at TDC No.1 cyl.
Ensure the chain tensioner is fully retracted and
held in the retracted position using the pin
provided.
Component Description:
1. Camshaft Control Valve Removal Tool
This tool is double sided and therefore 2 tools in
one unit.
(A) enables the removal and refitting of the
Camshaft Control Valve prior to timing chain
removal or engine disassembly.
After removal of the electrical connections from the
Cam Control Valve solenoid remove the timing
cover and using the appropriate face of the tool on a
suitable wrench unscrew the Control Valve in a
clockwise direction as shown in (Fig.1).
Image 14
2. Camshaft Clamp (Exhaust & Inlet)
(B) and (C) are designed primarily for use on the later
Generation 3 engines and are designed to lock the
camshaft pulleys in position as shown in (Fig.2) and
(Fig.3).
Once the engine is set at TDC No.1 and the cam pulley
marks are aligned fit the exhaust clamp first.
Use an open ended wrench to gently turn the camshaft
to allow the clamp to fully engage with the sprocket
teeth. Fitting of the inlet camshaft clamp is as shown in
(Fig.3)
Image 13
3. Oil Pump Tensioner Locking Pin
(D) is the tensioner locking pin for the oil pump drive
chain tensioner on the Generation 3 engines. It is
required to lock the tensioner in its fully retracted
position when removing the oil pump drive chain.
Image 15
4. Tensioner Locking Pin 1.4 mm/Timing
Chain Tensioner
Both (E) and (F) are tensioner locking tools for the
main cam chain tensioner.
The tensioner type dictates which locking device is
used. Both tensioners can be locked prior to removal
of the lower chain cover via an access window in
the chain cover as shown in (Fig.5) and (Fig.6).
4-1 Type A shown below use (E), for type A use a
small screwdriver inserted in to the tensioner in the
direction shown to release the plunger and push the
tensioner plunger fully back, insert (E) to lock the
plunger as shown in (Fig.5).
Image 16
Image 16
4-2 Type B shown in (Fig.6) uses locking tool (F).
Release the tensioner retaining clip and push the
plunger back to its fully retracted position. Insert (F)
as shown to lock the tensioner.
Image 17
Image 18
5-1 (G) is used, in conjunction with a suitable Dial
Gauge Metric (8 mm deflection) for use with (G), to
locate the TDC No.1 cylinder position.
Assemble (G) and the dial gauge together and secure
the dial gauge in place using the thumb screw on the
positioning tool.
Screw the (B) into the thread of spark plug hole of
No.1 cylinder and turn the engine over slowly, by
hand, in normal direction of engine rotation.
TDC position is achieved when the needle reaches its
highest reading and starts to move in the opposite
direction.
5-2 Check that TDC position has been achieved
correctly by checking the position of the holes in the
rear of the camshafts are positioned as (Fig.7). If they
are not in this position turn the crankshaft one more
rotation (360°)
Image 19
6. Dial Test Indicator
Top Dead Center (TDC) measurement must be
checked, this set includes TDC Adaptor (used in
conjunction with a Dial Test Indicator) which enables
the accurate measurement of the piston position.
Image 20
Image 20
7. Crank Counter Hold Tool & Crankshaft
Thrust Piece
Removing
7-1 Remove front noise insulation.
7-2 Take electrical connector -1- for radiator fan out
of bracket and unplug connector (push retainer to
the rear -arrow- and press down release catch).
7-3 Move clear electrical wiring harness going to
radiator fan control unit.
7-4 Unplug electrical connectors -2- and -3-.
Note: Some versions have only one radiator fan.
7-5 Unscrew bolt -arrow- and remove radiator fan
control unit -1-.
Caution: If a used belt runs in the opposite direction
when it is refitted, this can cause breakage. Before
removing, mark direction of rotation of poly V-belt
with chalk or felt-tip pen for re-installation.
7-6 To slacken poly V-belt turn tensioner in
direction of -arrow-.
7-7 Lock tensioner with locking pin -T10060A-.
7-8 Take off poly V-belt.
Caution: Risk of irreparable damage to engine.
To avoid disturbing valve timing, do not turn
crankshaft out of “TDC” position when vibration
damper is removed.
7-9 Turn vibration damper to “TDC” position
-arrow- using (I).
Notch on vibration damper must align with arrow
marking on cover for timing chains (bottom).
7-10 Remove bolt for vibration damper using (I).

Image 21
7-11 Detach vibration damper and fit (J) in its place.
7-12 Pull out oil seal.
Installing
Tightening torques
7-13 Clean contact surface and sealing surface.
7-14 Remove (J).
Image 22
8. Drift for Camshaft Slide Pieces
Note:
-Sealing surfaces at bottom of cylinder head cover
and top of cylinder head must not be machined.
-The camshaft bearings are integrated into the
cylinder head and cylinder head cover. The timing
chain must be slackened before removing the
cylinder head cover.
-Fit cable ties in the original positions when
installing.
8-1 Perform service position
8-2 Remove engine cover panel -arrows-.
8-3 Detach air duct at bottom together with air hose.
8-4 Disconnect hose -1- from air cleaner.
8-5 Disconnect air intake hose -2-.
8-6 Pull air cleaner housing upwards -arrows-.
8-7 Plug openings in turbocharger with sealing plugs
from engine bung set.
8-8 Unplug electrical connectors -arrows- at actuators
for camshaft adjustment.
8-9 Detach electrical connector for Lambda probe -1-
from retainer.
8-10 Release electrical connectors at ignition coils
and unplug from ignition coils simultaneously.
8-11 Remove bolts for ignition coils and pull out
ignition coils.
8-12 Remove actuators for camshaft adjustment
-arrows-.
8-13 Disconnect crankcase breather hose -1-.
8-14 Remove bolts -arrows-, detach crankcase
breather system and disconnect from crankcase
breather hose -2- in direction of -arrow-.
8-15 Disconnect pipe -arrows-.
8-16 Unplug electrical connector -1- from Hall
sender -G40-
8-17 Unplug connector -1- from exhaust camshaft
control valve 1 -N318- and connector -2- from
exhaust camshaft control valve 1 -N205-.
8-18 Unscrew bolts -arrows- and remove camshaft
control valve 1 -N205- and exhaust camshaft control
valve 1 -N318-.
8-19 Unscrew bolts -1 to 6- and remove timing chain
cover (top).
Caution: The timing valves have a left-hand thread.
8-20 Turn assembly tool -T10352/2- in direction of
-arrow- to remove timing valve (left and right sides).
8-21 Remove bolts -arrows- and detach bearing
saddle.
8-22 Turn vibration damper to “TDC” position
-arrow- using (I).
-Notch on vibration damper must align with arrow
marking on cover for timing chains (bottom).
-The markings -1- on the camshafts must face
upwards.

Caution: Risk of irreparable damage to engine.
Only insert assembly pins (K) in points marked in
illustration.
Image 23
8-23 Insert assembly pins (K) as shown in
illustration.
8-24 Turn crankshaft 2 rotations in direction of
engine rotation.
Note: Engine must be at “TDC” position again.
8-25 Remove assembly pins (K).

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