Volkswagen Workshop Service and Repair Manuals

Removing and installing camshaft timing chain and intermediate shaft drive chain

Special tools and workshop equipment required

t	Camshaft bar -T10068 A-

t	Counterhold tool -T10069-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Sealant -D 176 501 A1-

Removing timing chains: –  Remove gearbox → Rep. gr.34. –  Remove flywheel → Chapter. –  Remove sump → Chapter. –  Remove intake manifold → Chapter. –  Remove cylinder head cover → Chapter. –  Remove thermostat housing → Chapter.

–  Remove hose -3- and vacuum hose -2- from combi-valve for secondary air system. –  Pull off coolant hose -1-.

–  Mark and unplug electrical connections. 1 -  Hall sender -G40- 2 -  Hall sender 2 -G163- 3 -  Inlet camshaft control valve 1 -N205- 4 -  Exhaust camshaft control valve 1 -N318- –  Unscrew cable routing from camshaft timing chain cover.

–  Turn crankshaft at vibration damper in direction of engine rotation to TDC No. 1 cylinder -arrow- .

–  Cams -A- of cylinder 1 must face each other.

–  Insert camshaft bar -T10068 A- in both shaft grooves. If necessary, move the camshafts back and forth slightly with an open-end spanner.

–  Unscrew chain tensioner for camshaft timing chain -arrow-.

–  Undo and remove bolts -1 … 3- and pull cover off cylinder head horizontally. When doing so, ensure that cylinder head gasket is not damaged.

–  Unscrew bolts and remove timing chain bottom cover -arrow- horizontally from cylinder block. When doing so, ensure that cylinder head gasket is not damaged. –  Press seal for crankshaft - on timing chain side - out of cover. –  Remove camshaft bar -T10068 A-.

–  Loosen and remove bolt -arrow-.

–  To do this, counterhold vibration damper using counterhold -T10069-. –  Remove small sprocket with camshaft timing chain. –  Carefully withdraw camshaft timing chain behind web of cylinder head gasket.

Drive chain for intermediate shaft –  Unscrew chain tensioner for intermediate shaft drive chain -arrows-. –  Remove large sprocket with intermediate shaft drive chain.   Note If the camshaft adjusters and guide rails are also to be renewed, carry out this work before refitting the timing chains.

Installing drive chain and chain tensioner for intermediate shaft: –  Set crankshaft to TDC for No. 1 cylinder. Ground tooth of drive sprocket -arrow- must align with bearing joint. –  Turn intermediate shaft with flattened side upwards. –  Insert drive chain into guide rail and place onto crankshaft.

–  Insert large chain sprocket into drive chain so that lug on chain sprocket aligns with lug behind -B- on cylinder block. –  Fit large chain sprocket with drive chain attached onto intermediate shaft. When installing, ensure that drive chain runs completely straight in guide rail from crankshaft to intermediate shaft. l  Ground tooth of drive chain sprocket -arrow A- must align with bearing joint. l  Lug on chain sprocket of intermediate shaft must align with lug behind -arrow B-. –  If large chain sprocket cannot be fitted, turn intermediate shaft slightly.

–  Fit small chain sprocket of intermediate shaft. Installation is only possible in one position. –  Tighten bolt -arrow- hand-tight only as small chain sprocket has to be taken off again.

–  Install chain tensioner for drive chain. To do this, release locking teeth of chain tensioner with a small screwdriver and press tensioning plate against chain tensioner.   Note If a transport lock is fitted, do not remove until installation is complete.

–  Install chain tensioner in this position and tighten to 8 Nm -arrows-.

Installing camshaft timing chain: Prerequisite l  The camshaft adjusters are installed l  Cams -A- of cylinder 1 face each other.

–  Insert camshaft bar -T10068 A- in both shaft grooves.

–  Remove small chain sprocket on intermediate shaft. The large chain sprocket must not be pulled off. –  Guide camshaft timing chain from above between tensioning plate and guide rail towards intermediate shaft.   Note t  The 3 copper-coloured chain links next to each other must be placed on the intermediate shaft chain sprocket. t  The new camshaft timing chain may contain an additional copper-coloured link. Please ignore this link.

–  Turn inlet camshaft adjuster -A- to left as far as stop.

–  Place camshaft timing chain onto guide rail and camshaft adjuster. 2 individual copper-coloured links -C- must align with markings on camshaft adjuster. –  Fit small chain sprocket of intermediate shaft into camshaft timing chain. Marking -B- must align with middle copper coloured chain link -A-.

–  Fit small chain sprocket with camshaft timing chain attached onto intermediate shaft. Installation is only possible in one position. Hand-tighten new securing bolt -arrow-.

–  Lock vibration damper using counterhold -T10069-.

–  Tighten securing bolt for intermediate shaft chain sprockets -arrow- to 60 Nm + 90° (1/4 turn) further. Turning further can be done in several stages.   Note

When turning the crankshaft, the tensioning plate must be pressed firmly against the camshaft timing chain by hand (instead of by means of the chain tensioner) -arrow- to prevent the chain from jumping.

Check position of crankshaft relative to intermediate shaft. l  Ground tooth of drive chain sprocket -arrow A- must align with bearing joint. l  Lug on chain sprocket of intermediate shaft -arrow B- must align with lug behind.

Checking position of copper-coloured chain links relative to adjustment markings: l  Copper-coloured chain links -A- and -C- must align with adjustment markings.

Checking position of crankshaft relative to intermediate shaft: l  „Arrow“-1- on the camshaft adjuster of the inlet camshaft must align with the left notch -2- on the control housing.

l  The marking -1- on the camshaft adjuster of the exhaust camshaft must align with the left notch -2- on the valve timing housing.

–  Press tensioning plate firmly against camshaft timing chain by hand (instead of by means of the chain tensioner) and rotate crankshaft two revolutions in direction of engine rotation.   Note The copper coloured chain links no longer align with the adjustment markings once the crankshaft has been turned. If all the adjustment markings match, the further assembly process can continue.

–  Remove old sealant from 3 mm holes in cylinder head gasket -arrows-.   Note With the cylinder head installed, the holes in the cylinder head gasket are only half visible. –  Clean sealing surfaces on engine and both covers; they must be free of oil and grease.

–  Check if dowel pins for bottom cover for timing chains are inserted in cylinder block. –  Coat -hatched- clean sealing surfaces of cover thinly with sealant -D 176 501 A1-.   Note The bottom cover for the timing chains must be fitted within 5 minutes of applying the sealant.

–  Locate bottom cover -arrow- and tighten securing bolts alternately in several stages.

–  Fill 3 mm holes in cylinder head gasket -arrows- with sealant -D 176 501 A1-. –  In event of leaks, fit new seals in top cover for timing chains → Fig.

–  Check whether dowel sleeves -2- and -3- are inserted in top cover for timing chains. –  Fit new seal -1- and new gasket -4-. –  Coat sealing surface of cover with sealant -D 176 501 A1- and immediately install.

–  Locate top cover for timing chains and tighten all securing bolts slightly. Then tighten bolts as follows: t  Tighten bolts -1- and -2- to 5 Nm. t  Tighten bolts -3- to 23 Nm. t  Tighten bolts -1- and -2- to 10 Nm. –  Install chain tensioner for camshaft timing chain and tighten to 40 Nm. –  Install thermostat housing → Chapter. –  Install cylinder head cover and intake manifold → Chapter. Specified torques

Component		Nm
Bolts for guide rail to cylinder block		10
Chain tensioner to cylinder block		8
Sprockets to intermediate shaft		60 + 90°
Camshaft adjuster to camshafts		60 + 90°
Bottom cover for timing chains to cylinder block		10
Top cover for camshaft timing chain	M6	10
	M8	23
Chain tensioner for camshaft timing chain to cylinder head		40