Engine-Cpta-Czca-Czea-Ea211-Eng (2) (079-150)

Polo 2010 ➤ , Polo 2014 ➤ , Polo Lim RUS 2016 ➤
4-cyl. direct injection (1.4 l, 4V, EA 211, turbocharger) - Edition 11.2018
– Unscrew plug for “TDC” hole in cylinder block.

– Screw locking pin - T10340- into cylinder block as far as stop
and tighten to 30 Nm.
– Rotate crankshaft in normal direction of rotation as far as stop.
• The locking pin now rests against the crank web.
Note
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation only.
Setting piston from cylinder no. 1 to TDC position for repair work
on toothed belt drive and for setting valve timing
– Remove resonator for intake air
⇒ “3.3 Removing and installing resonator for intake air”, page
309 .
– Remove air intake pipe
⇒ “2.5 Removing and installing air intake pipe”, page 289 .
– Press release tabs, and disconnect hose -1- for activated

charcoal filter.
– Unscrew bolts -arrows- and pull off crankcase breather hose.
Note
Risk of chemical damage to the coolant pump gasket caused by

oil entering between the coolant pump and the cylinder head.
– Cover coolant pump with a cloth.

– Remove connection for turbocharger
⇒ “1.4 Removing and installing connection for turbocharger”,
page 279 .
– Lay wiring harness to one side -arrows-.

– Unscrew bolts -1, 3- and remove cover -2- for toothed belt for
coolant pump.
4. Pistons and conrods 73

– Unscrew bolts -arrows- and detach sealing cap -1-.
Vehicles without ACT:

• The asymmetrically positioned grooves on gearbox end of
both camshafts -top arrows- must now be above the horizontal
centre line.
• Grooves -arrows- on exhaust camshaft -A- can be accessed
through recesses in drive wheel for coolant pump.
• On inlet camshaft -E-, grooves -arrows- are above horizontal
camshaft centre line.
A - Exhaust camshaft
E - Inlet camshaft
– If the camshafts are not positioned as described: Unscrew
locking pin - T10340- . Turn crankshaft one revolution further
until camshaft is in right position.
Vehicles with ACT:

• On exhaust camshaft, hole -arrow- in toothed belt pulley for
coolant pump must align with hole in camshaft housing.
• On inlet camshaft, grooves -arrows- must be positioned above
centre of camshaft.
A - Exhaust camshaft
E - Inlet camshaft
– If the camshafts are not positioned as described: Unscrew
locking pin - T10340- . Turn crankshaft one revolution further
until camshaft is in right position.
74 Rep. gr.13 - Crankshaft group

Plug for “TDC” drilling in cylinder block - specified torque

♦ Renew O-ring if damaged.
♦ Tighten bolt -arrow- to 30 Nm.
Torque settings
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 270
♦ ⇒ “2.1 Assembly overview - charge air system”, page 283
♦ ⇒ “1.1 Assembly overview - ignition system”, page 348
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 307
♦ ⇒ “1.2 Assembly overview - camshaft housing”, page 78
4. Pistons and conrods 75

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 76
⇒ “1.2 Assembly overview - camshaft housing”, page 78
⇒ “1.3 Removing and installing cylinder head”, page 81
⇒ “1.4 Removing and installing camshaft housing”, page 85
⇒ “1.5 Checking compression”, page 88
1.1 Assembly overview - cylinder head
1 - Cylinder head gasket

❑ Renewing
⇒ “1.3 Removing and in‐
stalling cylinder head”,
page 81
❑ Observe installation po‐
sition: Part number to
cylinder head
2 - Dowel sleeve
❑ Qty. 2
3 - Cylinder head
❑ Removing and installing
stalling cylinder head”,
page 81
❑ Check for distortion
⇒ page 77 .
4 - Dowel pins
5 - Seal
❑ With oil strainer
❑ Inserted into cylinder
head
Note
♦ The oil strainer is fitted only if the

cylinder head has the appropri‐
ate recess.
♦ Cylinder heads without recess
do not require an oil strainer.
6 - Seal
❑ Renew after removal
7 - Camshaft case
❑ Removing and installing ⇒ “1.4 Removing and installing camshaft housing”, page 85
❑ The camshafts must not be removed individually.
❑ In the event of repair, the camshaft housing must be renewed completely.
8 - Bolt
❑ Specified torque and tightening sequence ⇒ page 81
76 Rep. gr.15 - Cylinder head, valve gear

9 - Bolt
❑ Sequence when loosening ⇒ page 84 .
Cylinder head - specified torque and sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts in stages in the sequence shown.

Stage Bolts Specified torque/turning further angle
1. -1 … 10- 40 Nm
2. -1 … 10- Turn 90° further
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.05 mm
1. Cylinder head 77
1.2 Assembly overview - camshaft housing

⇒ “1.2.1 Assembly overview - camshaft housing, vehicles with
Active Cylinder Management”, page 78
⇒ “1.2.2 Assembly overview - camshaft housing, exhaust side
with toothed belt pulley”, page 80
1.2.1 Assembly overview - camshaft housing, vehicles with Active Cylinder Man‐
agement
1 - Bolt
❑ 8 Nm
2 - Exhaust cam actuator for
cylinder 2 - N587-
stalling cam actuators”,
page 187
3 - Exhaust cam actuator for
cylinder 3 - N595-
page 187
4 - Inlet cam actuator for cylin‐
der 3 - N591-
page 187
5 - Inlet cam actuator for cylin‐
der 2 - N583-
page 187
6 - Bolts
❑ 4 Nm
7 - Hall sender 3 - G300-
⇒ “1.4.2 Removing and
installing Hall sender 3
G300 ”, page 353
8 - Hall sender - G40-
❑ Removing and installing ⇒ “1.4.1 Removing and installing Hall sender G40 ”, page 352
9 - O-ring
❑ Check for damage, and renew if necessary; see ⇒ Electronic parts catalogue (ETKA)
10 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing
⇒ “3.2.5 Removing and installing exhaust camshaft oil seal, gearbox end, vehicles with Active Cylinder
Management”, page 153
11 - Crankshaft
❑ For coolant pump

⇒ “2.7 Removing and installing toothed belt pulley for coolant pump”, page 245
12 - Bolt
❑ Specified torque ⇒ Item 8 (page 233)
13 - Bolt
❑ 8 Nm
14 - Cap
15 - Seal
❑ Renew
16 - Dowel pin
17 - Seal
❑ Inserted into cylinder head
Note

ate recess.
18 - Seal
❑ For inlet camshaft
❑ Renewing ⇒ “3.2 Removing and installing camshaft oil seal”, page 145
19 - Seal
❑ For exhaust camshaft
20 - Camshaft case
❑ Removing and installing ⇒ “1.4 Removing and installing camshaft housing”, page 85
21 - Cap
22 - Bolt
23 - Inlet camshaft control valve 1 - N205-
❑ Removing and installing ⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”, page 178
❑ With O-ring
❑ Check O-ring for damage.
❑ O-ring cannot be renewed individually; renew together with camshaft control valve 1 - N205- if damaged.
24 - Exhaust camshaft control valve 1 - N318-
⇒ “3.6 Removing and installing exhaust camshaft control valve 1 N318 ”, page 179
❑ With O-ring
❑ Check O-ring for damage.
❑ O-ring cannot be renewed individually; renew together with camshaft control valve 1 - N205- if damaged.
1. Cylinder head 79
Camshaft housing - specified torque and tightening sequence
Note

1. -1 … 15- 10 Nm
2. -1 … 15- Turn 180° further
1.2.2 Assembly overview - camshaft housing, exhaust side with toothed belt pul‐
ley
1 - Bolt
❑ Specified torque and
tightening sequence
⇒ page 81
2 - Inlet camshaft control valve
1 - N205-
stalling camshaft control
valve 1 N205 ”,
page 178
❑ With O-ring
❑ Check O-ring for dam‐
age.
❑ O-ring cannot be re‐
newed individually; re‐
new together with cam‐
shaft control valve 1 -
N205- if damaged.
3 - Bolt
❑ 8 Nm
4 - Camshaft case
stalling camshaft hous‐
ing”, page 85
5 - Hall sender - G40-
⇒ “1.4.1 Removing and
installing Hall sender
G40 ”, page 352
6 - Bolt
❑ 8 Nm
7 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing
⇒ “3.2.6 Removing and installing exhaust camshaft oil seal, gearbox end; exhaust side with toothed belt
pulley on control end”, page 155

8 - Crankshaft
❑ For coolant pump
⇒ “2.7 Removing and installing toothed belt pulley for coolant pump”, page 245
9 - Bolt
❑ Specified torque ⇒ Item 8 (page 233)
10 - Bolt
❑ 8 Nm
11 - Cap
12 - O-ring
13 - Seal
❑ Renew
14 - Dowel pin
15 - Seal
❑ Inserted into cylinder head
Note

ate recess.
16 - Seal
❑ For inlet camshaft
17 - Seal
❑ For exhaust camshaft (pulley end)
18 - Cap
Camshaft housing - specified torque and tightening sequence
Note

1. -1 … 15- 10 Nm
2. -1 … 15- Turn 180° further
1.3 Removing and installing cylinder head

Special tools and workshop equipment required
1. Cylinder head 81
♦ Bit XZN 12 - T40270-
Removing
Note
♦ Cover the opening in the gearbox with a cloth so that no fluids

can enter the gearbox housing.
♦ Fit all heat shield sleeves in the same place when installing.
♦ Cover the openings in the gearbox with a cloth to prevent any
fluid entering the clutch housing.
– Remove camshaft housing

⇒ “1.4 Removing and installing camshaft housing”,
page 85 .
– Remove intake manifold
⇒ “4.2 Removing and installing intake manifold”, page 312 .
– Release connectors and pull them off.
1- On oil pressure switch for reduced oil pressure - F378-
2- On fuel pressure sender - G247-
3- On injectors -N30- to -N33-
– Unscrew bolt -2-.

– Remove screw-type clip -1-.
– Unscrew nuts -arrows- and tie up catalytic converter -3-.
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .

– Remove heat-shield sleeve.

– Separate electrical connector -arrow- on oil pressure switch -
F1- .
– Unscrew bolts -arrows- and detach oil supply pipe -1- and oil
return pipe -2-.
– Release and pull off connectors -1- and -2-.

1 - For coolant temperature sender - G62-
2 - For charge pressure positioner - V465-
– Unscrew bolt -1- from engine support.
1. Cylinder head 83
– Loosen cylinder head bolts in the sequence -1 to 10- and un‐

screw.
– Take off cylinder head and set it down on a soft surface (foam
plastic).
Installing
Note
♦ Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block.
♦ Ensure that no long scores or scratches are made on the sur‐
faces.
♦ Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ Risk of leaks in cylinder head gasket.
♦ Carefully remove remains of emery and abrasives.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
♦ Renew bolts that are tightened with turning further angle.
♦ Renew self-locking nuts as well as gaskets, seals and O-rings.
♦ When installing a replacement cylinder head, the contact sur‐
faces between hydraulic compensation elements, roller rocker
fingers and cams must be oiled before installing the camshaft
housing.
♦ Secure all hose connections with hose clips corresponding to
the series equipment ⇒ Electronic Parts Catalogue .
♦ When cylinder head or cylinder head gasket is renewed, the
entire coolant and the engine oil must be changed.

– Fit cylinder head gasket -1-.

♦ Note centring pins in cylinder block -arrows-.
♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
– If the crankshaft has been turned in the meantime, proceed as
follows:
– Position piston of no. 1 cylinder to TDC.
– Turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Tighten bolts for cylinder head ⇒ page 77 .
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
Continue installation in reverse order of removal. The following

should be observed:
– Install camshaft housing
⇒ “1.4 Removing and installing camshaft housing”,
page 85 .
– Install intake manifold
⇒ “4.2 Removing and installing intake manifold”, page 312 .
– Change engine oil ⇒ Maintenance ; Booklet .
– Fill cooling system with fresh coolant
⇒ “1.3 Draining and adding coolant”, page 225 .
Torque settings
♦ ⇒ Fig. ““Engine support - specified torque and tightening se‐
quence”“ , page 23
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 76
♦ ⇒ “4.2 Removing and installing intake manifold”, page 312
♦ ⇒ Fig. ““Installing catalytic converter - specified torque and
tightening sequence”“ , page 343
♦ Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Assembly overview - drive shaft .
1.4 Removing and installing camshaft hous‐

ing
Removing
– Remove coolant pump
⇒ “2.5 Removing and installing coolant pump”, page 238 .
– Remove air filter housing
⇒ “3.2 Removing and installing air filter housing”, page 308 .
– Remove ignition coils
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 349 .
1. Cylinder head 85
– Remove toothed belt from camshafts

⇒ “2.7 Removing toothed belt from camshaft”, page 133 .
– Disconnect electrical connector -1-.
– Detach hose clip -2- and pull off hose.
– Remove high-pressure pipe -3-
⇒ “7.3 Removing and installing high-pressure pipe”,
page 331 .
– Disconnect electrical connector -1-.
– Install connecting piece
page 279 .
– Unscrew bolts -arrows-.

– Swivel coolant lines -1- to side.
– Unscrew bolts or nuts -arrows-.

– Unclip wiring harness for lambda probe from heat shield -1-.
– Remove heat shield -1-.
– Release and pull off connector -arrow- on intake manifold

sender - GX9- .

– Release connectors and pull them off.

– The number of connectors varies.
1 - For cam actuators - N583/ N587/ N591/ N595-
2 - For Hall sender - G40- and Hall sender 3 - G300-
4 - For camshaft control valve 1 - N205- and exhaust camshaft
control valve 1 - N318-
– Unscrew bolt -3- and lay wiring harness to one side.
– Pull out dipstick -5-.
– Loosen bolts for camshaft housing in the sequence -15 to 1-

and unscrew.
– Carefully detach camshaft housing from adhesive bond and
remove it.
– Mark allocation of roller rocker fingers and compensation ele‐
ments for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and place them on a clean surface.
Installing
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew gasket and seal with oil strainer.
– Set engine to “TDC for cylinder no. 1”

⇒ “2.5 Checking valve timing”, page 109 .
NOTICE
Risk of damage to valve gear caused by axial movement of the
camshafts.
– Never move camshafts in axial direction when turning them.
– Check, if all roller rocker fingers are seated properly on valve

stem end and if their clipped into the respective compensation
element.
Note
♦ The oil strainer is fitted only if the cylinder head has the ap‐
propriate recess.
♦ Cylinder heads without recess do not require an oil strainer.
– Fit seal with oil strainer -2- into cylinder head -1-.
– Fit gasket onto dowel pins -arrows-.
1. Cylinder head 87
– Screw 2 studs -items 2, 4- (e.g. -T10288/4- ) into cylinder head.

– Carefully lower camshaft housing -3- vertically onto studs in
cylinder head.
Note
Ensure that camshaft housing is not canted.
– Tighten bolts for camshaft housing ⇒ page 81 .

Continue installation in reverse order of removal. The following
should be observed:
– Install high-pressure pipe
⇒ “7.3 Removing and installing high-pressure pipe”,
page 331 .
– Install toothed belt (adjust valve timing)
⇒ “2.7 Removing toothed belt from camshaft”, page 133 .
– Install ignition coils
page 349 .
– Install coolant pump
– Ensure proper connection and routing of wires ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Torque settings
♦ ⇒ “3.1 Assembly overview - valve gear”, page 144
1.5 Checking compression

♦ Spark plug socket - 3122 B-

♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.5 V.
– Remove fuse for fuel pump control unit from fuse holder. Fuse
assignment ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Start engine and allow it to run until the engine turns off.
– Switch off ignition.
309 .
1. Cylinder head 89
– Pull off connector -2- and unscrew bolt -1-.

– Pull out ignition coils with output stages.
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Check compression pressure using compression tester -
V.A.G 1763- ; refer to ⇒ Operating instructions .
– Get a second mechanic to press down the accelerator pedal.
– Simultaneously operate starter until tester shows no further
pressure increase.
– Repeat procedure on each cylinder.
Compression pressures bar
New 10.0 … 15.0
Wear limit 7.0
Maximum difference between cylinders 3.0
Installing
Assembly is carried out in reverse sequence; note the following:
– Install spark plugs. Specified torque 22 Nm.
– Install ignition coils with output stages
page 349 .
– Entries will have been made in the event memory of the engine
control unit because connectors were separated and the en‐
gine was started.
– Carry out the function Generate readiness code on ⇒ Ve‐
hicle diagnostic tester in Guided functions mode.

2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt cover”, page 91
⇒ “2.2 Assembly overview - toothed belt”, page 92
⇒ “2.3 Removing and installing toothed belt guard”, page 95
⇒ “2.4 Preassembling and installing valve timing tool”,
page 96
⇒ “2.5 Checking valve timing”, page 109
⇒ “2.6 Adjusting valve timing”, page 115
⇒ “2.7 Removing toothed belt from camshaft”, page 133
⇒ “2.8 Removing and installing toothed belt”, page 138
2.1 Assembly overview - toothed belt cover
1 - Lower toothed belt guard

2 - Bolt
❑ 8 Nm
3 - Engine support
tightening sequence
⇒ “2.1 Assembly over‐
view - assembly mount‐
ings”, page 21
4 - Bolt
tightening sequence
⇒ “2.1 Assembly over‐
view - assembly mount‐
ings”, page 21
5 - Upper toothed belt guard
6 - Bolt
❑ 8 Nm
2. Toothed belt drive 91

2.2 Assembly overview - toothed belt

⇒ “2.2.1 Assembly overview - toothed belt, exhaust side with
camshaft adjuster”, page 92
⇒ “2.2.2 Assembly overview - toothed belt, exhaust side with
toothed belt pulley”, page 94
2.2.1 Assembly overview - toothed belt, exhaust side with camshaft adjuster
1 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
❑ Check for wear ⇒ Main‐
tenance ; Booklet 3.1
stalling toothed belt”,
page 138
❑ Adjusting valve timing
⇒ “2.6 Adjusting valve
timing”, page 115
2 - Bolt
❑ 25 Nm
❑ When setting the speci‐
fied torque on the torque
wrench - VAS 6583- ,
the length indicated on
the insert tool - T10500-
must be entered in the
torque wrench.
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
stalling engine support”,
page 43 .
4 - Bolt
❑ 8 Nm +45°
5 - Cap
6 - Bolt Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ 50 Nm +135°
7 - Exhaust camshaft toothed belt pulley
❑ With camshaft adjuster
❑ Removing and installing camshaft adjuster
⇒ “3.3 Removing and installing camshaft adjuster”, page 157
8 - Guide bush
9 - Inlet camshaft toothed belt pulley

10 - Bolt
❑ Renew
❑ 50 Nm +135°
11 - O-ring
12 - Plug
❑ 20 Nm
❑ Renew
13 - Spacer sleeve
❑ With O-ring
❑ Renew O-ring
❑ Supplied with “item 14”
14 - Idler roller
15 - Bolt
❑ 40 Nm
16 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
Note
Renew O-ring if damaged.
– Tighten bolt -arrow- to 30 Nm.

2.2.2 Assembly overview - toothed belt, exhaust side with toothed belt pulley
1 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
❑ Check for wear ⇒ Main‐
tenance ; Booklet 3.1
stalling toothed belt”,
page 138
❑ Adjusting valve timing
⇒ “2.6.1 Adjusting valve
timing, vehicles without
ACT”, page 115
2 - Bolt
❑ 25 Nm
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
stalling engine support”,
page 43 .
4 - Bolt
❑ Renew
❑ 50 Nm +90°
5 - Exhaust camshaft toothed
belt pulley
⇒ “2.7 Removing tooth‐
ed belt from camshaft”,
page 133
6 - Inlet camshaft toothed belt
pulley
7 - Guide bush
8 - Bolt
❑ Renew
❑ 50 Nm +135°
9 - O-ring
10 - Plug
❑ 20 Nm
❑ Renew
11 - O-ring
❑ Captive, supplied with “item 13”.
❑ Renew

12 - Spacer sleeve
❑ Supplied with item “13”.
❑ Renew
13 - Idler roller
14 - Bolt
❑ 40 Nm
15 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
Note
Renew O-ring if damaged.
– Tighten bolt -arrow- to 30 Nm.
2.3 Removing and installing toothed belt

guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page
95
⇒ “2.3.2 Removing and installing lower toothed belt guard”, page
95
2.3.1 Removing and installing upper toothed

belt guard
Removing:
– Detach hoses from retainer -3-.
– Unscrew bolt -2-.
– Release clips -arrows- and remove upper toothed belt guard
-1-.
Installing:
Install in reverse order of removal. Observe the following:
Specified torques:
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
2.3.2 Removing and installing lower toothed

belt guard
Removing:
– Remove vibration damper
⇒ “1.5 Removing and installing vibration damper”, page 41 .

– Unscrew bolts -arrows-.

– Remove lower part of toothed belt guard.
Installing:
Install in reverse order of removal. Observe the following:
– Install vibration damper
⇒ “1.5 Removing and installing vibration damper”, page 41 .
Specified torques:
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
2.4 Preassembling and installing valve tim‐

ing tool
⇒ “2.4.1 Preassembling test tool VAS 611 007 without ACT”, page
96
⇒ “2.4.2 Preassembling test tool VAS 611 007 with ACT”,
page 99
⇒ “2.4.3 Mounting test tool VAS 611 007 without ACT”,
page 102
⇒ “2.4.4 Mounting test tool VAS 611 007 with ACT”, page 104
⇒ “2.4.5 Teaching-in test tool VAS 611 007 electronically and
performing basic setting”, page 107
2.4.1 Preassembling test tool - VAS 611 007-

without ACT
♦ Tester for checking elongation of chain links - VAS 611 007-
Procedure
Test tool - VAS 611 007-

A - Angle sensor - VAS 611

007/1-
❑ Specified torque brake:
11 Nm
B - Lock ring - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/8-
E - Adapter for angle sensor -
VAS 611 007/9- and adapter
for angle sensor - VAS 611
007/10-
❑ Adapter for angle sen‐
sor - VAS 611 007/9-
blue, for inlet camshaft
sor - VAS 611 007/10-
red, for exhaust cam‐
shaft
Preassembling test tool - VAS 611 007-

– Before installing the adapters for angle sensor -E- in angle
sensors -A-, check correct assignment by means of the colour
coding -a-.
– Insert corresponding adapter for angle sensor -E- in relevant
angle sensors -A-.
– Note position of dowel pins -a- when installing.

– Adapters for angle sensors -E- can only be fitted in one posi‐
tion.
– Make sure that brake -b- is released. Do not apply force.
– Insert adapter for angle sensors -E- in angle sensors -A- as

far as stop.
– Secure clamp rings -C- in groove -a- of respective adapter for
angle sensors -E-.
– Insert angle sensor -A- colour coded red on red marked side
-arrows a- of camshaft housing adapter -D-. To do this, release
locking pin -c- by pulling it upwards.
– Insert angle sensor -A- colour coded red and push in until
locking pin -c- can be heard to engage.
– Repeat procedure with angle sensor -A- colour coded blue.
– To do this, observe colour coding -arrows b-.
– Screw in red and blue lock ring -B- approx. 2 turns. Note colour
coding -arrows a- and -arrows b- when doing this.
Note
♦ Screw in securing rings - VAS 611 007/2- -B- max. 2 turns by

hand.
♦ If the securing rings are screwed in too tightly -B-, the angle
sensors - VAS 611 007/1- could become damaged.

– Check for freedom of movement of the adapters for angle

sensors.
• It should be possible to turn adapters for angle sensors with
ease.
2.4.2 Preassembling test tool - VAS 611 007-

with ACT
♦ Adapter - VAS 611 007/14- (not illustrated)

A - Angle sensor - VAS 611

007/1-
❑ Specified torque brake:
11 Nm
B - Lock ring - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/8-
E - Adapter for angle sensor -
VAS 611 007/9- and adapter
for angle sensor - VAS 611
007/14-
sor - VAS 611 007/9-
blue, for inlet camshaft
sor - VAS 611 007/14-
red, for exhaust cam‐
shaft
Preassembling test tool - VAS 611 007-

– Insert angle sensor -A- colour coded red -arrow a- on red
marked side -arrow a- of camshaft housing adapter -D-. To do
this, release locking pin -C- by pulling it upwards.
– Insert angle sensor -A- colour coded red and push in until
locking pin -C- can be heard to engage.
– Repeat procedure with angle sensor -arrow b- colour coded
blue.
– Before installing the adapters for angle sensor -E- in angle
sensors -A-, check correct assignment by means of the colour
coding -a and b-.
– Insert corresponding adapter for angle sensor -E- in relevant
angle sensors -A-.

– To do this, insert adapter for angle sensor - VAS 611 007/9-

-E- in angle sensor - VAS 611 007/1- -A- with blue colour
coding -arrows a-.
• Adapters for angle sensors -E- can only be fitted in one posi‐
tion.
– Note position of dowel pins -a- when installing.

– Make sure that brake -b- is released. Do not apply force.
Note
The adapter for angle sensor - VAS 611 007/14- cannot be moun‐
ted until the angle sensor - VAS 611 007/1- is mounted in the
camshaft housing adapter - VAS 611 007/8- .
Insert adapter for angle sensor - VAS 611 007/14- -E- in angle
sensor - VAS 611 007/1- -A- with red colour coding -arrows a-.
– Insert adapter for angle sensors -E- in angle sensors -A- as

far as stop.
– Secure clamp rings -C- in groove -a- of respective adapter for
angle sensors -E-.
– To do this, observe colour coding -arrows-.

– Screw in red and blue lock ring -B- approx. 2 turns. Note colour
coding -arrows a- and -arrows b- when doing this.
Note
♦ Screw in securing rings - VAS 611 007/2- -B- max. 2 turns by

hand.
♦ If the securing rings are screwed in too tightly -B-, the angle
sensors - VAS 611 007/1- could become damaged.
– Check for freedom of movement of the adapters for angle

sensors.
• It should be possible to turn adapters for angle sensors with
ease.
2.4.3 Mounting test tool - VAS 611 007- with‐

out ACT
Procedure
– Preassemble test tool - VAS 611 007-
⇒ “2.4.1 Preassembling test tool VAS 611 007 without ACT”,
page 96 .
– Teach-in test tool - VAS 611 007- electronically and perform
basic setting
– Turn adapter for angle sensor - VAS 611 007/9- and adapter
for angle sensor - VAS 611 007/10- until display is set to ap‐
prox. 0°.
Polo 2010 LHD vehicles, Polo 2014 LHD vehicles, Polo Lim RUS
2016:
– Remove brake master cylinder ⇒ Brake system; Rep. gr. 47 ;
Brake servo/brake master cylinder; Removing and installing
brake master cylinder .
Continued for all vehicles:
– Perform the preliminary work for checking the valve timing
– Make sure that the piston in cylinder no. 1 is at TDC position
⇒ “4.7 Setting piston to TDC position”, page 71 .
– Make sure that brakes on angle sensor - VAS 611 007/1- are
released on both sides ⇒ page 98 .

Note
Before positioning the test tool - VAS 611 007- against the cam‐
shaft housing, the grooves of the camshafts must be checked for
damage.
– Align adapter for angle sensor -E- by hand with grooves of

camshafts -arrows-.
– Check proper alignment through recess, and adapt position by
turning.
– Fit adapter for camshaft housing - VAS 611 007/8- -D- to cam‐
shaft housing, and slide it on.
– Tighten knurled screws -arrows a- alternately by hand.
– Make sure that adapter for camshaft housing - VAS 611 007/8-
-D- is properly seated.
Note
♦ If camshaft housing adapter - VAS 611 007/8- -D- touches the

housing of the coolant pump, the basic setting of the coolant
pump is incorrect.
♦ In this case, correct adjustment or testing of the valve timing
is not possible.
♦ The coolant pump must be removed and readjusted
• Test tool - VAS 611 007- must rest flush against camshaft
housing.
– Tighten locking ring - VAS 611 007/2- -B- on both sides evenly
by hand. When doing this, ensure that camshaft housing
adapter - VAS 611 007/8- -D- always lies flat against camshaft
housing -1-.

• Camshaft housing adapter - VAS 611 007/8- -D- should not lift
off of camshaft housing -1-.
Note
The correct preload is achieved when the camshaft housing

adapter - VAS 611 007/8- lies flat -a- against the camshaft hous‐
ing.
– Make sure that brakes -a- are released on both sides.
2.4.4 Mounting test tool - VAS 611 007- with

ACT
Procedure
⇒ “2.4.2 Preassembling test tool VAS 611 007 with ACT”, page
99 .
– Teach-in test tool - VAS 611 007- electronically and perform
basic setting
– Turn adapter for angle sensor - VAS 611 007/9- and adapter
for angle sensor - VAS 611 007/14- until display is set to ap‐
prox. 0°.

2016:
– Remove brake master cylinder ⇒ Brake system; Rep. gr. 47 ;
Brake servo/brake master cylinder; Removing and installing
brake master cylinder .
Continued for all vehicles:
– Perform the preliminary work for checking the valve timing
Note
Before positioning the test tool - VAS 611 007- -D- against the
camshaft housing, the grooves of the camshafts must be checked
for damage.
– Align adapter for angle sensor - VAS 611 007/9- -E- by hand
to grooves of camshafts -arrows b-.
– Align adapter for angle sensor - VAS 611 007/14- -F- by hand
in hole of coolant pump toothed belt sprocket -arrow a-.
– Check position of adapter for angle sensor - VAS 611 007/9-
-E- and adapter for angle sensor - VAS 611 007/14- -F-
through inspection window and adjust if necessary by turning.

– Fit adapter for camshaft housing - VAS 611 007/8- -D- to cam‐
shaft housing, and slide it on.
– Tighten knurled screws -arrows a- alternately by hand.
– Make sure that adapter for camshaft housing - VAS 611 007/8-
-D- is properly seated.
Note
♦ If camshaft housing adapter - VAS 611 007/8- -D- touches the

housing of the coolant pump, the basic setting of the coolant
pump is incorrect.
♦ In this case, correct adjustment or testing of the valve timing
is not possible.
♦ The coolant pump must be removed and readjusted
• Test tool - VAS 611 007- must rest flush against camshaft
housing.
– Tighten locking ring - VAS 611 007/2- -B- on both sides evenly
by hand. When doing this, ensure that camshaft housing
adapter - VAS 611 007/8- -D- always lies flat against camshaft
housing -1-.
• Camshaft housing adapter - VAS 611 007/8- -D- should not lift
off of camshaft housing -1-.
Note
The correct preload is achieved when the camshaft housing

adapter - VAS 611 007/8- lies flat -a- against the camshaft hous‐
ing.

2.4.5 Teaching-in test tool - VAS 611 007-

electronically and performing basic set‐
ting
Procedure
– Connect electronic measuring equipment of test tool - VAS
611 007- ⇒ Operating manual .
– Perform software installation of test tool - VAS 611 007- ⇒
Operating manual .
– Start test program ⇒ Operating manual .
If angle sensors are not connected, message shown in illustration
is displayed.
– Connect test tool - VAS 611 007- , and press CONNECT .
If test tool - VAS 611 007- is connected, display is as shown:

ANW - Exhaust camshaft, red
ENW - Inlet camshaft, blue

– Turn adapter for angle sensor - VAS 611 007/10- red -E- for
exhaust camshaft.
If »OK« is displayed, exhaust camshaft has been taught-in.
– Turn adapter for angle sensor - VAS 611 007/9- blue -E- for
inlet camshaft.
If display is as shown in illustration, exhaust camshaft has been

taught-in.
– Select function MEASURE .
If display is as follows:
– Check valve timing.
⇒ “2.5 Checking valve timing”, page 109
– Make sure that brake indicator on display is green.

• It must not be yellow or red.
A - Green, brake is released
B - Yellow, brake is applied
C - Red, brake has been tightened to torque

2.5 Checking valve timing

⇒ “2.5.1 Checking valve timing, vehicles without ACT”,
page 109
⇒ “2.5.2 Checking valve timing, vehicles with ACT”, page 112
2.5.1 Checking valve timing, vehicles without

ACT
Procedure
309 .
– Remove air pipe
page 279 .
– Set piston for cylinder no. 1 to TDC position
– Drain coolant
– Unscrew bolts -2-.
– Remove cover for thermostat housing -1-.

– Unclip wiring harness -3- and place to one side.

– Place a cloth underneath to catch any oil which may drain out.
– Take off cap -5-.
– Pull off pipe -2-.
– Remove toothed belt cover -4-.
⇒ “2.4.1 Preassembling test tool VAS 611 007 without ACT”,
page 96 .
– Install test tool - VAS 611 007-
⇒ “2.4.3 Mounting test tool VAS 611 007 without ACT”,
page 102 .
– Make sure that brake indicator on display is green -A-.


– Unscrew locking pin - T10340- -A-.

– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw in locking pin - T10340- -A-.
– Read valve timing angles on display, and compare values with

specifications.
Specified values
Inlet camshaft Exhaust camshaft
-0.5° ±1.5° +1.5° ±1.5°
Note
♦ Adjust valve timing as precisely as possible. The settings must

be as close to the specifications as possible.
♦ The valve timing must not be outside the tolerance limits.
– If necessary, adjust timing.

– Add coolant ⇒ “1.3 Draining and adding coolant”, page 225 .
2016:
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system .
Torque settings
page 232
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder

Component Torque setting

Bolt for TDC hole 30 Nm
in cylinder block
2.5.2 Checking valve timing, vehicles with

ACT
Procedure
309 .
– Remove air pipe
page 279 .
– Drain coolant
– Remove cover for thermostat housing -1-.

– Unclip wiring harness -3- and place to one side.

– Place a cloth underneath to catch any oil which may drain out.
– Take off cap -5-.
– Pull off pipe -2-.
– Remove toothed belt cover -4-.
⇒ “2.4.2 Preassembling test tool VAS 611 007 with ACT”, page
99 .
– Install test tool - VAS 611 007-
⇒ “2.4.4 Mounting test tool VAS 611 007 with ACT”,
page 104 .
– Make sure that brake indicator on display is green -A-.



– Screw in locking pin - T10340- -A-.
– Read valve timing angles on display, and compare values with

specifications.
Specified values
-1.3° ±1.5° +0.8° ±1.5°
Note

– If necessary, adjust timing.

– Add coolant ⇒ “1.3 Draining and adding coolant”, page 225 .
2016:
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system .
Torque settings
page 232
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder

Component Torque setting

Bolt for TDC hole 30 Nm
in cylinder block
2.6 Adjusting valve timing

⇒ “2.6.1 Adjusting valve timing, vehicles without ACT”,
page 115
⇒ “2.6.2 Adjusting valve timing, vehicles with Active Cylinder
Management”, page 124
2.6.1 Adjusting valve timing, vehicles without

ACT
♦ Locating bolt - T10340-
♦ Engine bung set - VAS 6122-
Procedure
• Toothed belt installed.
– Check valve timing ⇒ “2.5 Checking valve timing”, page 109 .
– Do not relieve tension from toothed belt, and do not remove
toothed belt from camshafts when adjusting valve timing. Only
loosen camshaft adjuster or toothed belt sprocket.
– Loosen camshaft adjuster on inlet side ⇒ page 164 .
Exhaust side with toothed belt sprocket
– Loosen toothed belt sprocket on exhaust side ⇒ page 175 .
Exhaust side with camshaft adjuster
– Loosen camshaft adjuster on exhaust side ⇒ page 170 .

Continuation for all vehicles
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
– Place a cloth under the camshaft adjusters and over tension‐

ing roller to catch the engine oil which runs out.
• The contact points between the toothed belt and components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.
• Catch any engine oil which runs out immediately, and remove
it.
• Remove engine oil at camshaft adjusters.
– Renew bolt -2- and screw in loosely.

Continued for all vehicles
• It should still be possible to turn the camshaft adjuster and
toothed belt sprocket on the camshafts.
Setting camshafts to »0°«:

– Make sure that bolts -a- for brakes are released on both sides.

– Make sure that the brake indicator on the display is »green«

-A-.
– Display must not be »yellow« or »red«.
– Set both camshafts to »0.0°«.
– To do this, turn camshafts with adapter for angle sensor - VAS

611 007/5- -E-.
– Hold camshafts via adapter for angle sensor - VAS 611 007/9-
and adapter for angle sensor - VAS 611 007/10- -E- in »0.0°«
position with a wrench.
Note
♦ The camshafts tend to turn.

♦ Use a hexagon key to hold the camshafts in 0.0° position.
♦ Always remove the hexagon key after the camshafts have
been tightened.
– Tighten brakes after adjustment has been completed.

– Tighten bolts -a- for brakes to 11 Nm on both sides.

– Make sure that the brake indicator on the display is »red«

-C-.
– Display must not be »yellow« or »green«.

– Tighten camshaft adjuster on inlet camshaft to specified initial
torque ⇒ Fig. ““”“ , page 166 .


-A-.
– Seal camshaft adjuster -2- using suitable plugs -A- from en‐
gine bung set - VAS 6122- .
– Fit a piece of paper -A- into plugs to catch the engine oil.
– Insert plugs into camshaft adjusters with the open side facing
towards front, as shown in illustration.
Determining correction angle
– Screw in locking pin - T10340- .
– Read valve timing on display and write down values.
1. Measurement example: value reading on display
Note
♦ The correction angle is determined for each individual vehicle.

♦ The value read after the engine has been cranked is used for
determining the correction angle.
♦ Note the algebraic signs of the values.
♦ The correction angle results from the difference between the
specification and the value which has been read after the
crankshaft has been cranked twice.
♦ The correction angle is used to adjust the valve timing.
♦ The difference between the actual value (read after 2 full rev‐
olutions of the engine) and the specification is calculated.
♦ The result is the correction angle to be set, with the corre‐
sponding algebraic sign/direction of rotation.

Example
Index Explanation
e Inlet camshaft - actual value (after 2 full revolutions
of the engine)
f Inlet camshaft - specification (+/- tolerance)
c Direction of correction (+/-)
d Correction value - correction angle
a Exhaust camshaft - actual value (after 2 full revolu‐
tions of the engine)
b Exhaust camshaft - specification (+/- tolerance)
Angle in ° Inlet camshaft Exhaust camshaft

Specified angle -0.5°±1.5° +1.5°±1.5°
– Set determined correction angle for camshafts.

Setting valve timing with correction angle
– Place a cloth underneath camshaft adjuster to catch any en‐
gine oil which runs out.
– Remove plug taken from engine bung set - VAS 6122- from
camshaft adjuster.
– Remove paper from plugs and camshaft adjusters.
– Clean camshaft adjusters with a cleaning cloth and remove as
much engine oil as possible.
NOTICE


– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
are released on both sides.

-A-.
– Set the two camshafts to the determined correction angle

⇒ page 119 .
611 007/9- and adapter for angle sensor - VAS 611 007/10-
-E-.
If the valve timing has been set:

– Tighten bolts -a- for brakes on test tool - VAS 611 007- to
11 Nm on both sides.

– Make sure that brake indicator on display is red -C-.


– Tighten toothed belt sprocket of exhaust camshaft to specified
initial torque ⇒ page 176 .
– Tighten camshaft adjuster of exhaust camshaft to specified
– Release brakes -a- on both sides.


-A-.
– Seal camshaft adjusters -1- and -2- using suitable plugs -A-
from engine bung set - VAS 6122- .
– Fit a new piece of paper into plugs -A- to catch the engine oil.
– The plug for the camshaft adjuster -1- on exhaust side must
be pushed in slightly.
Note

– Read valve timing, and compare it with specifications.
Specified angle in °
-0.5° ±1.5° +1.5° ±1.5°
– If the valve timing is not OK, adjust valve timing again.

– Unscrew locking pin - T10340- .
– Make sure that brakes on test tool - VAS 611 007- are released
on both sides.
– Tighten camshaft adjuster on inlet camshaft to specified final
final torque ⇒ page 176 .


Torque settings
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 92
page 232
2.6.2 Adjusting valve timing, vehicles with Ac‐

tive Cylinder Management
♦ Engine bung set - VAS 6122-
Procedure
• Toothed belt installed.
– Do not relieve tension from toothed belt, and do not remove
toothed belt from camshafts when adjusting valve timing. Only
loosen camshaft adjuster or toothed belt sprocket.

NOTICE
– Place a cloth under the camshaft adjusters and over tension‐

ing roller to catch the engine oil which runs out.
• The contact points between the toothed belt and components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.
• Catch any engine oil which runs out immediately, and remove
it.
• Remove engine oil at camshaft adjusters.

• It should still be possible to turn the camshaft adjuster and
toothed belt sprocket on the camshafts.
Setting camshafts to »0°«:



-A-.
– Set both camshafts to »0.0°«.

611 007/5- -E-.
– Hold camshafts via adapter for angle sensor - VAS 611 007/9-
and adapter for angle sensor - VAS 611 007/10- -E- in »0.0°«
position with a wrench.
Note
♦ The camshafts tend to turn.

♦ Use a hexagon key to hold the camshafts in 0.0° position.
♦ Always remove the hexagon key after the camshafts have
been tightened.
– Tighten brakes after adjustment has been completed.

– Tighten bolts -a- for brakes to 11 Nm on both sides.

– Make sure that the brake indicator on the display is »red«

-C-.



-A-.
– Seal camshaft adjuster -2- using suitable plugs -A- from en‐
gine bung set - VAS 6122- .
– Fit a piece of paper -A- into plugs to catch the engine oil.
– Insert plugs into camshaft adjusters with the open side facing
towards front, as shown in illustration.
Determining correction angle
– Read valve timing on display and write down values.
1. Measurement example: value reading on display
Note
♦ The correction angle is determined for each individual vehicle.

♦ The value read after the engine has been cranked is used for
determining the correction angle.
♦ Note the algebraic signs of the values.
♦ The correction angle results from the difference between the
specification and the value which has been read after the
crankshaft has been cranked twice.
♦ The correction angle is used to adjust the valve timing.
♦ The difference between the actual value (read after 2 full rev‐
olutions of the engine) and the specification is calculated.
♦ The result is the correction angle to be set, with the corre‐
sponding algebraic sign/direction of rotation.

Calculation example ACT

Example
Index Explanation
e Inlet camshaft - actual value (after 2 full revolutions
of the engine)
f Inlet camshaft - specification (+/- tolerance)
c Direction of correction (+/-)
d Correction value - correction angle
a Exhaust camshaft - actual value (after 2 full revolu‐
tions of the engine)
b Exhaust camshaft - specification (+/- tolerance)
Angle in ° Inlet camshaft Exhaust camshaft

Specified angle -1.3°±1.5° +0.8°±1.5°
– Set determined correction angle for camshafts.

Setting valve timing with correction angle
– Place a cloth underneath camshaft adjuster to catch any en‐
gine oil which runs out.
– Remove plug taken from engine bung set - VAS 6122- from
camshaft adjuster.
– Remove paper from plugs and camshaft adjusters.
– Clean camshaft adjusters with a cleaning cloth and remove as
much engine oil as possible.
NOTICE


– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
are released on both sides.

-A-.
– Set the two camshafts to the determined correction angle

⇒ page 119 .
611 007/9- and adapter for angle sensor - VAS 611 007/10-
-E-.
If the valve timing has been set:

– Tighten bolts -a- for brakes on test tool - VAS 611 007- to
11 Nm on both sides.

– Make sure that brake indicator on display is red -C-.


– Release brakes -a- on both sides.


-A-.
– Seal camshaft adjusters -1- and -2- using suitable plugs -A-
from engine bung set - VAS 6122- .
– Fit a new piece of paper into plugs -A- to catch the engine oil.
– The plug for the camshaft adjuster -1- on exhaust side must
be pushed in slightly.
Note

– Read valve timing, and compare it with specifications.
Specified angle in °
-1.3° ±1.5° +0.8° ±1.5°
– If the valve timing is not OK, adjust valve timing again.

– Unscrew locking pin - T10340- .
– Make sure that brakes on test tool - VAS 611 007- are released
on both sides.


Torque settings
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 92
page 232
2.7 Removing toothed belt from camshaft
Special tools and workshop

equipment required
♦ Torque wrench - VAS 6583-

♦ Counterhold - T10172- with adapter -T10172/1-
♦ Counter-hold tool - T10475-
♦ Special wrench, 30 mm - T10499-
♦ Insert tool - T10500-

♦ Release tool - T10527-

♦ Release tool - T10527/1-
Removing
– Set piston of no. 1 cylinder to “TDC” position.
⇒ “4.7 Setting piston to TDC position”, page 71
– Remove upper part of toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 95 .
– Remove lower toothed belt guard
⇒ “2.3.2 Removing and installing lower toothed belt guard”,
page 95 .
– Loosen plug and securing bolt for camshaft adjuster on inlet
side
⇒ “3.3 Removing and installing camshaft adjuster”,
page 157 .
– Loosen securing bolt of toothed belt pulley on exhaust side by
approx. one turn ⇒ page 175 .
– Loosen securing bolt of camshaft adjuster on exhaust side by
Note
♦ If a used toothed belt runs in the opposite direction when it is

refitted, it may break.
♦ Before removing, mark direction of rotation of toothed belt with
chalk or felt-tipped pen for re-installation.
– Loosen securing bolt of tensioning roller -1- using insert tool,

13 mm - T10500- .
– Release tension on tensioning roller at eccentric -2- using
wrench - T10499- .
– Remove toothed belt.

– Detach crankshaft pulley -1- -arrow-.
Bend radius of toothed belt
NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
Installing
– Fit toothed belt -1- together with crankshaft pulley -2- onto
crankshaft journal.
• Milled surface of crankshaft sprocket -arrow- must be posi‐

tioned on milled surface of crankshaft stub.
• Contact surface between poly V-belt pulley and crankshaft
toothed belt pulley must be free of oil and grease.



• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
• Metal tab -arrow- of tensioning roller must engage in recess in

cylinder head.
Fit toothed belt in prescribed sequence:

– Pull toothed belt upwards and fit on idler pulley -1-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.

– Rotate eccentric -2- of tensioning roller using special wrench,

30mm -T10499- in -direction of arrow- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment win‐
dow.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting specified torque on torque wrench - VAS 6583- ,
length must be entered in torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm

using insert tool - T10500- with torque wrench - VAS 6583- .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviations do not affect the
toothed belt tension or the timing.
– Install lower part of toothed belt guard

page 95 .
– Adjust valve timing ⇒ “2.6 Adjusting valve timing”, page 115 .
final torque. ⇒ page 172
Further assembly is carried out in the reverse order of removal.
Specified torques:
• ⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
• ⇒ “2.2 Assembly overview - toothed belt”, page 92

• ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – specified

torque”“ , page 52
• ⇒ “1.2 Assembly overview - camshaft housing”, page 78
• ⇒ “3.1 Assembly overview - crankcase breather system”, page
209
• ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
• ⇒ “1.1 Assembly overview - turbocharger”, page 270
• ⇒ “2.1 Assembly overview - charge air system”, page 283
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation
2.8 Removing and installing toothed belt
Special tools and workshop

equipment required
♦ Torque wrench - VAS 6583-

♦ Counterhold - T10172- with adapter -T10172/1-
♦ Counter-hold tool - T10475-

♦ Special wrench, 30 mm - T10499-

♦ Insert tool - T10500-
♦ Release tool - T10527-

♦ Release tool - T10527/1-
Removing
– Set piston of no. 1 cylinder to “TDC” position.
⇒ “4.7 Setting piston to TDC position”, page 71
– Remove upper part of toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 95 .
– Remove lower toothed belt guard
page 95 .
– Loosen plug and securing bolt for camshaft adjuster on inlet
side
⇒ “3.3 Removing and installing camshaft adjuster”,
page 157 .
– Loosen securing bolt of toothed belt pulley on exhaust side by
– Loosen securing bolt of camshaft adjuster on exhaust side by
Note
♦ If a used toothed belt runs in the opposite direction when it is

refitted, it may break.
♦ Before removing, mark direction of rotation of toothed belt with
chalk or felt-tipped pen for re-installation.
– Loosen securing bolt of tensioning roller -1- using insert tool,

13 mm - T10500- .
– Release tension on tensioning roller at eccentric -2- using
wrench - T10499- .
– Remove toothed belt.

– Detach crankshaft pulley -1- -arrow-.
Bend radius of toothed belt
NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
Installing
– Fit toothed belt -1- together with crankshaft pulley -2- onto
crankshaft journal.
• Milled surface of crankshaft sprocket -arrow- must be posi‐

tioned on milled surface of crankshaft stub.
• Contact surface between poly V-belt pulley and crankshaft
toothed belt pulley must be free of oil and grease.



• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
• Metal tab -arrow- of tensioning roller must engage in recess in

cylinder head.
Fit toothed belt in prescribed sequence:

– Pull toothed belt upwards and fit on idler pulley -1-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.

– Rotate eccentric -2- of tensioning roller using special wrench,

30mm -T10499- in -direction of arrow- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment win‐
dow.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting specified torque on torque wrench - VAS 6583- ,
length must be entered in torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm

using insert tool - T10500- with torque wrench - VAS 6583- .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviations do not affect the
toothed belt tension or the timing.
– Install lower part of toothed belt guard

page 95 .
– Adjust valve timing ⇒ “2.6 Adjusting valve timing”, page 115 .
final torque. ⇒ page 172
Further assembly is carried out in the reverse order of removal.
Specified torques:
• ⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
• ⇒ “2.2 Assembly overview - toothed belt”, page 92

• ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – specified

torque”“ , page 52
• ⇒ “1.2 Assembly overview - camshaft housing”, page 78
• ⇒ “3.1 Assembly overview - crankcase breather system”, page
209
• ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
• ⇒ “1.1 Assembly overview - turbocharger”, page 270
• ⇒ “2.1 Assembly overview - charge air system”, page 283
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 144
⇒ “3.2 Removing and installing camshaft oil seal”, page 145
⇒ “3.4 Removing and installing toothed belt pulley”, page 173
⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”,
page 178
⇒ “3.6 Removing and installing exhaust camshaft control valve 1
N318 ”, page 179
⇒ “3.7 Removing and installing valve stem seals”, page 179
⇒ “3.8 Removing and installing cam actuators”, page 187
3.1 Assembly overview - valve gear
1 - Inlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 192
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 191
2 - Outlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 192
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 191
3 - Cylinder head
4 - Valve stem seal
❑ Renewing
stalling valve stem
seals”, page 179
5 - Valve springs
❑ Fitting position
⇒ page 145
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker fingers
stalling camshaft hous‐
ing”, page 85
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.

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Polo 2010 ➤ , Polo 2014 ➤ , Polo Lim RUS 2016 ➤

4-cyl. direct injection (1.4 l, 4V, EA 211, turbocharger) - Edition 11.2018

– Unscrew plug for “TDC” hole in cylinder block.

Locking pin - T10340- locks crankshaft in direction of engine ro‐

– Press release tabs, and disconnect hose -1- for activated

Risk of chemical damage to the coolant pump gasket caused by

– Cover coolant pump with a cloth.

– Lay wiring harness to one side -arrows-.

4. Pistons and conrods 73

– Unscrew bolts -arrows- and detach sealing cap -1-.

Vehicles without ACT:

Vehicles with ACT:

74 Rep. gr.13 - Crankshaft group

Plug for “TDC” drilling in cylinder block - specified torque

4. Pistons and conrods 75

15 – Cylinder head, valve gear

1.1 Assembly overview - cylinder head

1 - Cylinder head gasket

♦ The oil strainer is fitted only if the

76 Rep. gr.15 - Cylinder head, valve gear

Cylinder head - specified torque and sequence

Renew bolts that are tightened with turning further angle.

– Tighten bolts in stages in the sequence shown.

Checking cylinder head for distortion

1.2 Assembly overview - camshaft housing

78 Rep. gr.15 - Cylinder head, valve gear

♦ The oil strainer is fitted only if the

Camshaft housing - specified torque and tightening sequence

Renew bolts that are tightened with turning further angle.

– Tighten bolts in stages in the sequence shown.

80 Rep. gr.15 - Cylinder head, valve gear

♦ The oil strainer is fitted only if the

Camshaft housing - specified torque and tightening sequence

Renew bolts that are tightened with turning further angle.

– Tighten bolts in stages in the sequence shown.

1.3 Removing and installing cylinder head

♦ Bit XZN 12 - T40270-

♦ Cover the opening in the gearbox with a cloth so that no fluids

– Remove camshaft housing

– Unscrew bolt -2-.

82 Rep. gr.15 - Cylinder head, valve gear

– Remove heat-shield sleeve.

– Release and pull off connectors -1- and -2-.

– Unscrew bolt -1- from engine support.

– Loosen cylinder head bolts in the sequence -1 to 10- and un‐

♦ Risk of damage to sealing surfaces.

84 Rep. gr.15 - Cylinder head, valve gear

– Fit cylinder head gasket -1-.

After repair work it is not necessary to retighten the cylinder head

Continue installation in reverse order of removal. The following

1.4 Removing and installing camshaft hous‐

– Remove toothed belt from camshafts

– Unscrew bolts -arrows-.

– Unscrew bolts or nuts -arrows-.

– Release and pull off connector -arrow- on intake manifold

86 Rep. gr.15 - Cylinder head, valve gear

– Release connectors and pull them off.

– Loosen bolts for camshaft housing in the sequence -15 to 1-