Struggling to align camshaft sprokets holes with TDC Camshaft

I am struggling to align camshaft sprokets holes with TDC Crankshaft for my VW Passat 2006 2.0tdi. After finding the Cranshaft TDC using the VW aligning/locking pin I expected to slot in the camshaft locking pins with relative ease. But it soon became clear that they were out of alignment. Only a small diameter drill bit can be wholly inserted to the left sprocket hole and the other is completely out. Now that I have removed the old cambelt and I am now fitting the new one I am determined to make sure the engine is well timed. Should I wiggle the 18mm bolts with the crankshaft locked? is there any damaged I could do by so doing?

Who can lend me the tool for fitting the Rear end crankshaft seal as I have to fi a new on with the sensor. This tool costs around £300. Far too expensive for me. Any advice welcome.

Just to add' last night I had to cut the 100mm hexa-pin for the engine oil pump because it's too long to fit in the 77mm hole. What is the purpose of this new pin length? At 100k miles the old one had started to round off. My intention is to replace the whole balance-shafts pump with the chain driven one in a year or 2.

100mm pin is for cars with a deeper hex broaching in the balance shaft. To set the cams you have to release the M8 (13mm) bolts and tweak the cams back or forth using an 18mm spanner.

Thank you Crasher. It actually worked. I released those 13mm bolts and wriggled the cams and the pins fitted. I have now competed that part and refitting the oil pump, and then the crankshaft seal I damaged earlier.

The crank seal is a pain. I have the genuine tool for the small engines and a fellow local VAG specialist friend of ours has the genuine big engine tool and we borrow each others as appropriate but most aftermarket versions are dual use. A T10134 or equivalent (http://www.lasertools.co.uk/items/PD...structions.pdf) is not cheap and is VITAL to do the job or the car probaly won't start. Remember that the oil seal must not be lubricated, it and the crank running face must be perfectly clean and dry.

I have now fitted the cambelt and the oil pump (with a new hexa-pin drive). I am now shifting my focus on the Crankshaft bearing. Will keep you all posted.

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Originally Posted by Crasher

The crank seal is a pain.

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Agree totally with you, bought my crankshaft seal tool from ebay for £80 early this year but like you said, is vital to do the job

Just to return to the story of my B6 2.0 dti that has been a project in very slow process for 8 months now; Quick feedback so far: 1) The crankshaft seal was fitted by a VW specialist friend of mine, 2) I have just about completed the painstaking task of putting things together. Just for clarity: the main reason it's taken this long is because I go to work Monday to Friday and having a young family means that even my Saturdays are also taken as I have to take my son to football practice sessions. On Sundays I go to church and come back at noon. Occasionally I find an hour or 2 to work on the car. I have renewed the front lower suspension in preparation for MOT. In another two days I hope to start the car. Hopefully it will start and save me over £3000 as quoted by VW Lancaster. I hope to return soon to say whether the car is on the road.

I know it's a bit late to write the conclusion to the story of my attempts to carry out major DIY repairs on my precious B6 Passat, but I just want all to know that this project was completed. I even replaced the water pump and cambelt. Imagine my delight when the engine roared at the first cranking with the starter! This work saved me over £2000 according to the VW dealership. More than anything, I learned a lot. It was mission completed, and I moved on to other ventures.