Volkswagen Workshop Service and Repair Manuals

Removing and installing timing chain and chain drive for oil pump (engine codes BKG, BLN)

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Dial gauge adapter -T10170-

t	Camshaft clamp -T10171-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t  Spark plug socket and extension -3122 B-

t  Counterhold tool -3415- t  Torque wrench (5…50 Nm) -V.A.G 1331- Removing –  Remove air filter → Chapter. –  Remove exhaust gas recirculation valve -N18- and unscrew camshaft sealing cover → Chapter. –  Remove spark plug from No. 1 cylinder. To do this, use puller -T10094 A- and spark plug wrench -3122 B-.

–  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.

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

–  Install a M6 bolt -arrow- hand-tight (do not tighten) to secure camshaft clamp -T10171-. –  Remove valve timing housing → 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. –  Unscrew bolts -2- and -4- and remove chain sprocket -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 securing bolt -1- to 20 Nm + 90° further.

–  Position chain tensioner on oil pump drive chain and tighten securing bolt -3- to 15 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.   Note The illustration shows the timing chain with camshaft adjuster. The procedure of work is as follows:

–  Place timing chain -1- on crankshaft chain sprocket -4- and exhaust camshaft chain sprocket -3- and tighten inlet camshaft chain sprocket -2- hand-tight using a new bolt.   Note Note running direction mark on timing chain -1-.

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.

–  Hold camshaft sprockets -1- and -5- in this position with counterhold -T10172- then tighten bolts -2- and bolt -4- to 50 Nm.   Note Securing bolts -2- and -4- are only tightened 90° further once timing has been checked.

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

–  Hold camshaft chain sprockets with counterhold -T10172- and tighten bolts -2- and -4- 90° further with a rigid wrench.   Note Camshaft sprockets must not move on camshaft whilst tightening.

–  Install oil pump wheel cover -1-. –  Install timing housing → Chapter. Further assembly is basically the reverse of the dismantling sequence.