Volkswagen Workshop Service and Repair Manuals

Removing and installing timing chain and chain drive for oil pump

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Dial gauge adapter -T10170- or dial gauge adapter -T10170 A-

t	Camshaft clamp -T10171 A-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t  Spark plug socket and extension -3122 B-

t  Counterhold tool -3415- t  Torque wrench -V.A.G 1331- Removing

–  Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-. –  Remove air filter (Golf, Golf Plus, Eos, Scirocco, Touran, Tiguan, Sharan, Passat, Passat CC, Golf Cabriolet) → Chapter. –  Drain coolant (Golf, Golf Plus, Eos, Scirocco, Touran, Tiguan, Golf Cabriolet) → Chapter. –  Drain coolant (Sharan) → Chapter. –  Drain coolant (Passat, Passat CC) → Chapter.

–  Remove coolant hoses and line/wiring guides -arrows-. –  Unscrew securing bolts and remove camshaft sealing covers -1-. –  Remove spark plug from No. 1 cylinder. To do this, use puller -T10094 A- and spark plug socket and extension -3122 B- → Chapter.

–  Release and pull off connector -2-. –  Remove oil pressure switch -F1--1-.

–  Screw dial gauge adapter -T10170- into spark plug hole to stop. –  Screw dial gauge -VAS 6079- and extension -T10170/1- in to stop and lock in position with lock nut -arrow-. –  Turn crankshaft in direction of engine rotation, to TDC No. 1 cylinder. Note position of small needle on dial gauge.

The holes -arrows- in the camshaft must align as shown. Otherwise turn crankshaft one rotation (360°) further.   Note t  If crankshaft is turned more than 0.01 mm past TDC, then turn crankshaft back 45° against engine direction of rotation. Then turn crankshaft in direction of engine rotation to TDC No. 1 cylinder. t  Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.   Caution Before using camshaft clamp -T10171 A- you must check that the pins on the tool project by at least 7 mm. If this is not the case, the camshaft clamp is defective and must be renewed. The camshaft clamp must not be positioned using any kind of hammer.

–  Insert camshaft clamp -T10171 A- to stop in camshaft openings. Locking pins -arrows 1- must engage in holes -arrows 2-. Inscription „TOP“-arrow 3- must be readable from above.

–  Screw an M6 bolt hand-tight into corresponding bore -arrows- (but do not tighten) to secure camshaft clamp -T10171 A-.   Note Note that there are different securing points for the camshaft clamp -T10171 A-. Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet) → Chapter. Remove valve timing housing (Tiguan, Touran) → Chapter. Remove valve timing housing (Passat, Passat CC) → Chapter

–  Pull cover -1- off chain sprocket for oil pump.

–  Press tensioning rail in -direction of arrow- by hand and lock piston of chain tensioner with locking pin -T40011-.

–  Mark direction of rotation of timing chain -3- using coloured felt tip marker pen.   Note Camshaft adjuster securing bolt -2- has a left-hand thread. –  Unscrew bolts -2- and -4- and remove camshaft adjuster -1- together with timing chain -3-. Counterhold using counterhold -T10172-.

–  Hold oil pump chain sprocket with counterhold -T10172- and loosen securing bolt -1-.

–  Use a screwdriver on bolt -2- to release tensioning spring -1- then remove tensioning spring -1-. –  Unscrew securing bolt -3- and remove chain tensioner. –  Mark direction of rotation of oil pump drive chain -2- using felt-tip marker.

–  Remove securing bolt for chain sprocket -1- and remove chain sprockets -1- and -3- together with drive chain for oil pump -2-. Installing l  The crankshaft must be positioned at TDC No. 1 cylinder.

–  Push chain sprocket -1- in -direction of arrow- onto crankshaft journal as far as the stop.   Caution Cast lug -2- on chain sprocket -1- must seat in groove -3- on crankshaft journal.

–  Mark position of chain sprocket and crankshaft to cylinder block using a felt-tip marker.

–  Place oil pump drive chain -3- onto drive chain sprocket -1- and position drive chain sprocket -2- onto oil pump drive shaft at same time.   Note t  Note running direction mark on oil pump drive chain. t  Oil pump drive sprocket only fits on oil pump drive shaft in one position -arrow-.

–  Hold oil pump drive sprocket with counterhold -T10172-. –  Tighten new securing bolt -1- to 20 Nm + 1/4 turn (90°) further.

–  Position chain tensioner on oil pump drive chain and tighten securing bolt -3- to 8 Nm. –  Lever tensioning spring -1- onto bolt -2- using a screwdriver.   Note t  Note marks -arrows-. t  The crankshaft must not rotate. –  Tighten chain sprocket -3- hand-tight with new securing bolt.

–  Place timing chain -1- on crankshaft chain sprocket -4-, exhaust camshaft chain sprocket -3-, and tighten camshaft adjuster -2- hand-tight using a new securing bolt.   Note t  Note running direction mark on timing chain -1-. t  Ensure guide sleeve is installed between inlet camshaft and camshaft adjuster. t  Camshaft adjuster securing bolt -2- has a left-hand thread.

Timing chain must lie on guide rail -1- and crankshaft chain sprocket -arrow-.

–  Install chain tensioner -1- and tighten securing bolts -2- to 9 Nm. –  Tension timing chain by pulling locking pin -T40011- from chain tensioner. –  Check marks on crankshaft chain sprocket and cylinder block; they must align.

–  Tighten securing bolt -2- to 40 Nm and bolt -4- to 50 Nm (use counterhold -T10172-).   Note t  Securing bolts -2- and -4- are only tightened 90° further once timing has been checked. t  The camshaft adjuster securing bolt -2- has a left-hand thread.

–  Unscrew bolt -arrow- and remove camshaft clamp -T10171 A- from camshaft housing. –  Check valve timing → Chapter If valve timing is OK:

–  Hold camshaft sprockets with counterhold -T10172- and tighten securing bolts -2- (left-hand thread) and -4- 1/4 turn (90°) further with a rigid wrench.   Note Camshaft adjuster securing bolt -2- has a left-hand thread.   Note Camshaft sprockets must not move on camshaft whilst tightening.

–  Install oil pump wheel cover -1-. Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet) → Chapter. Remove valve timing housing (Tiguan, Touran) → Chapter. Remove valve timing housing (Passat, Passat CC) → Chapter –  Install crankshaft pulley → Chapter. –  Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet) → Chapter. –  Install poly V-belt (Tiguan) → Chapter.

–  Push engine cover panel down at points -1- in direction of -arrow- until it engages. Further assembly is basically the reverse of the dismantling sequence.

Specified torque

Component	Specified torque
Oil pressure switch -F1-	25 Nm