Volkswagen Workshop Service and Repair Manuals

(Installing valve chains)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 3268 Camshaft bar
• ◆ 3273 Retainer
• ◆ VW 558 Counter-hold
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)

Work sequence

Engine removed

Install single chain and chain tensioner with tensioning plate:

• ‒ → Set/check position of crankshaft to intermediate shaft.
       Ground down tooth on crankshaft sprocket -B-
       must align with the main bearing joint (TDC No. 1 Cyl.).
• ‒ Install pin without collar for guide rail -2- and tighten to
       25 Nm.

• ‒ → Install guide rail -2- with single chain -1- and both sprockets -3- and -4- (note D.O.R. of single chain , Fig.1 )
       The marking on single chain sprocket -4-
       must align with the notch -C- or -D- on the
       thrust washer.
• ‒ Release locking spline in chain tensioner with a small screwdriver -A-.
• ‒ Press chain tensioner against tensioner plate and tighten chain tensioner to
       10 Nm.

Vehicles with manual gearbox

• ‒ Tighten flywheel to crankshaft with 3 old bolts and counter-hold with VW 558.

Vehicles with automatic gearbox

• ‒ Secure drive plate to crankshaft with 3 old bolts.

• ‒ → Secure counter-hold tool VW 558 behind the drive plate with a hexagon bolt M8x20.

Note:

On vehicles 08.95 ▸gearbox housing is installed without a cut-out forTDC mark.

Therefore the vibration damper is marked with aTDC No. 1 cylinder mark.

To prevent crankshaft from turning, e.g. when securing the flywheel or drive plate the counter-hold 3273 can be used.

• ‒ → Fit retainer 3273. When doing this the crankshaft may have to be moved away from TDC position.

Continuation for all vehicles

• ‒ → Tighten intermediate shaft sprockets 3 and 4
       100 Nm.
• ‒ Remove flywheel/drive plate and check position of crankshaft to intermediate shaft.

Install camshaft chain and chain tensioner with tensioning plate:

• ‒ → Locate camshafts with camshaft jig 3268.
• ‒ Install tensioning plate pivot pins and tighten to
       25 Nm.
• ‒ Install tensioning plate for chain tensioner (camshaft chain).
• ‒ Install locating pin with collar for guide rail and tighten to
       25 Nm.

Note:

With cylinder head removed:

• ‒ Installing cylinder head .

• ‒ Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6" and tighten both bolts to
       20 Nm.
• ‒ Place camshaft chain on intermediate shaft. (Note D.O.R. of chain
  => Page 13-8 , Fig.1 ).
• ‒ Fit camshaft sprocket and chain to camshaft for cylinder bank 2, 4 and 6 (short camshaft) and tighten by hand.
• ‒ Fit camshaft sprocket (with sender wheel for Hall sender) and chain to camshaft for cylinder bank 1, 3 and 5 and tighten by hand.

Notes:

• ◆ Contact surface of timing chain and sender wheel must be dry when installing.
• ◆ Oil head contact surface of bolts when installing.

• ‒ Remove camshaft jig 3268.

• ‒ Tighten securing bolts for camshaft sprockets to
       100 Nm.

→ Note:

Only counter-hold with 24 mm open jaw spanner on the camshaft -arrow-. The camshaft jig must not be fitted when tightening/loosening the sprockets.

• ‒ Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten securing bolt to
       10 Nm.
• ‒ Replace sealing flange oil seal
  => Page 13-39 , removing and installing sealing flange and flywheel/drive plate.
• ‒ Prepare cylinder head gasket for assembly
  => Page 15-8 , Fig. 2
• ‒ Coat camshaft sprocket cover sealing flange with AMV 188 001 02.
• ‒ Oil O-ring (=> Page 13-11 , Pos.11 ) and insert in camshaft sprocket cover.
• ‒ Install camshaft cover, insert all securing bolts and tighten lightly.
• ‒ First tighten M8 securing bolt to
       25 Nm
  then M6 securing bolts to
       10 Nm.
• ‒ Install chain tensioner for camshaft chain and tighten to
       30 Nm.

Notes:

• ◆ If the chain tensioner has been pulled apart (for double chain), bleed chain tensioner before installing
  , Fig. 3

• ◆ Only turn engine with chain tensioner installed! Otherwise single or double chain will jump over!

• ‒ Turn crankshaft two full turns in engine D.O.R. and check valve timing => Page 13-24 .

Engine installed, cylinder head removed

• ‒ → Set crankshaft to TDC No. 1 Cyl. marks -arrow- by turning crankshaft on the vibration damper securing bolt in engine D.O.R.:

→ If the TDC No. 1 Cyl. setting is correct it is possible to see a notch on the intermediate shaft sprockets -arrow-.

If the notch cannot be seen:

• ‒ Turn crankshaft one full turn in engine D.O.R.

Note:

If the crankshaft is turned with the cylinder head removed, a 2nd mechanic should guide the double chain by hand to prevent it jamming.

• ‒ → Locate camshafts with camshaft jig 3268.
• ‒ Prepare cylinder head gasket for assembly
  => Page 15-8 , Fig. 2
• ‒ Install cylinder head => Page 15-12
• ‒ Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6" and tighten bolts to
       20 Nm.
• ‒ Fit camshaft sprocket and double chain to camshaft for cylinder bank 2, 4 and 6 (short camshaft) and tighten by hand.
• ‒ Install camshaft sprocket (with sender wheel for Hall sender) and double chain on camshaft for cylinder bank 1, 3 and 5 and tighten by hand.

Notes:

• ◆ Contact surface of timing chain and sender wheel must be dry when installing.
• ◆ Oil head contact surface of bolts when installing.

• ‒ Remove camshaft jig 3268.
• ‒ Tighten securing bolts for camshaft sprockets to
       100 Nm.

→ Note:

Only counter-hold with 24 mm open jaw spanner on the camshaft -arrow-. The camshaft jig must not be fitted when tightening/loosening the sprockets.

• ‒ Coat sealing surface of sealing flange with AMV 188 001 02.
• ‒ Oil O-Ring (=> Page 13-11 , Pos.11 ) and insert in camshaft sprocket cover.
• ‒ Install camshaft cover, insert all securing bolts and tighten lightly.
• ‒ First tighten M8 securing bolt to
       25 Nm
  then M6 securing bolts to
       10 Nm.
• ‒ Install chain tensioner camshaft chain and tighten to
       30 Nm.

Notes:

• ◆ If the chain tensioner has been pulled apart, bleed chain tensioner before installing
  , Fig. 3
• ◆ Only turn engine with chain tensioner installed! Otherwise single or double chain will jump over!

• ‒ Turn crankshaft two full turns in engine D.O.R. and check valve timing => Page 13-24 .