Volkswagen Workshop Service and Repair Manuals

Removing timing chain –  Drain coolant → Chapter. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Mark the direction of rotation of the poly V-belt and remove belt → Chapter.

–  Open spring-type clips and pull coolant hoses -1- and -2- off. –  Push catch -3- underneath coolant hoses and pull hoses upwards. –  Put down coolant hoses to rear.

–  Pull both hoses -1- off non-return valve. –  Unscrew securing bolt -2- and pull non-return valve out of cylinder head cover.

–  Remove all securing bolts from valve timing housing cover -1-. –  Remove valve timing housing cover.

–  Remove securing bolts -1- and remove coolant pipe bracket -2-.

–  Unscrew plug -arrow- from cylinder block. –  Screw locking pin -T10340- to stop into crankcase. –  Turn crankshaft in normal direction of rotation until the stop.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as described below. –  Remove locking pin. –  Turn crankshaft 1/4 revolution (90°) in normal direction of rotation. –  Screw locking pin -T10340- to stop into crankcase. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in normal direction of rotation until the stop.

Locking pin -T10340- locks crankshaft in direction of engine rotation.

–  Insert locking pin -T10414- to stop in cylinder head cover. –  Tighten securing bolt -1- hand tight. –  Remove sump → Chapter.

–  Lever off dust cap -1- and remove idler roller. –  Remove coolant pump pulley. –  Hold pulley with water pump wrench -V.A.G 1590-.

–  Loosen securing bolt for crankshaft pulley. Hold pulley with counterhold tools -3415- and -3415/2-.

–  Loosen all securing bolts of valve timing housing -1-. –  Remove valve timing housing.

–  Unscrew chain tensioner -arrow- for timing chain. –  Mark direction of rotation of timing chain using coloured felt tip marker pen.

–  Loosen securing bolt -1- for camshaft chain sprocket. –  Hold camshaft sprocket with counterhold tool -T10172-. –  Remove camshaft sprocket together with securing bolt. –  Remove timing chain downwards. Installing timing chain → Chapter