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Discussion Starter · #1 ·
I am new here. I am a seasoned DIYer and I am fairly skilled in fixing my cars. This does not mean I make no mistakes though.

My V6 30V passat has reached 170k miles so I did the timing belt job the 2nd time to it. I did the first at 100k miles and all was OK. The engine started and idled smoothly. It rev'ed up fine too. So I think the job is successful. I also had the cam chain tensioner gaskets replaced and new valve cover gaskets put on. All seem to be OK.

However, I noticed something. I hand cranked the crankshaft to the position so that the 3rd cylinder is at TDC. I found that while the bank 2's cam is perfectly aligned but the bank 1's cam is slightly off. I only own a cam alignment locking tool for a different VW engine. It is about 6 inches too short for the Passat B5 V6 engine. But I can attach it to one cam gear at a time and check if the other end is perfectly lined up horizontally. In this case the bank 2 is perfectly horizontal but the bank 1 is slightly off.

When I did the belt job I mainly relied on marking the belt and counted the number of tooth between marks to make sure the new belt goes back to the same setup. But the bank 1's cam is slightly off. And it looks like if the belt is stretched over time it would become perfectly lined up. I don't think the belt will stretch and becomes longer though.

I tried to readjust the belt by one tooth. That's a lot of work but I did it anyway. The bank 1 was still off a little but to a different (worse) direction. As soon as the engine was started it threw a code of p0341. I took it apart and adjusted it back 1 tooth. The engine then ran fine and rev'ed up fine again. The problem is the bank 1 cam looks still slightly off. I think the ECU did not find the cam angle to be out of range yet. My question is should I just drive the car and forget about it? I have let the engine idle, rev'ed up and down for quite some time. There was no code thrown.

I can try to get a correct cam locking tool and have the cams perfectly aligned. But i hate to have to wait for the tool and take even longer to get the job done. OKI should get the tool and have it done right. I am still curious why the bank 1 cam is off slightly? The cam gears were never loosened so they are at the original factory setup still. There is no code thrown by the ECU. Very strange.

All suggestions welcome. Thanks.
 

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Discussion Starter · #8 ·
Thanks to everyone's input to this thread. All your suggestions are taken and I appreciate you all.

I do have a crankshaft locking tool and a camshaft alignment locking tool 5 inches too short but usable. The only tool I don't have is a cam sprocket puller. I might try a pair of short C-clamp and see if they can pull the sprocket off. The reason to try that is I can do it quickly without waiting 4 to 7 days of UPS time.

I repeatedly checked the camshaft alignment and the bank 2 looks reasonably accurate. The bank 1 is off a little. If I had a correct length alignment locking tool it would be almost 1 inch too low on the bank 2 end while the bank 1 end is attached to the camshaft. I would consider it OK if it were only 1 cm lower. I have decided to do it right to loosen the sprocket and align it accurately.

This is the 3rd time I did timing belt for VW/Audi V6 engine. The first time was for this same VW Passat 70k miles ago. The 2nd one was for my 2002 Audi Allroad with a 2.7T engine 5 months ago. I did the TB by marking the belt and counting the number of tooth method for the first and 2nd job without any problem. It is the 3rd time that I find that the bank 1 cam to be off alignment. I believe I could drive the Passat the way it is. But it is not that difficult to get it done right when I have everything torn apart right now.

I am still curious why the alignment is off this time. This is probably why. I did not replace anything else but the TB for the first two TB jobs. I know some of you will probably say bad idea. I made a decision not to replace anything else was based on a believe that my water pump, TB roller, tensioner roller etc. were OEM. They all turned smoothly with no play that I could feel. I did not want to replace them with new ones that might be made in China with longevity doubt. Those rollers and water pump are replaced from the Passat this time. They still turn smoothly with no play whatsoever. But I think they have done their duty and it's time to be swapped out. What I did not anticipate is the cam alignment goes off a little. The TB kit I use is a Dayco one. The reason I chose Dayco was because the OEM belt was a Dayco brand (both the Passat and the Audi 2.7T had the same Dayco TB). The Dayco TB is made in Italy.

So I am going to do it the right way this time. I will report back how it goes when it is done in a week or so. Thanks again for everyone's suggestions.
 
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