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-

t	Camshaft clamp -T10171-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t  Spark plug spanner -3122 B-

t  Counterhold tool -3415- t  Torque wrench (5...50 Nm) -V.A.G 1331- Removing

–  Remove camshaft housing cover by removing bolts -arrows-. –  Press locking devices -1- and pull air intake connecting piece out of air intake guide.

–  Remove spring-type clamp -2- using hose clip pliers -VAS 6340- or spring-type clip pliers -VAS 5024A- and pull air intake hose off air filter housing. –  Remove bolts for exhaust camshaft cover -3- and inlet camshaft cover -4- and pull covers out of camshaft housing. –  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 felt-tip marker. –  Remove bolts -2- and remove sprocket -1- 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-. –  Remove 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 chain sprocket -3- on chain sprocket -1- and simultaneously place chain sprocket -2- on oil pump drive shaft.   Note t  Note direction of rotation marks on oil pump drive chain. t  The oil pump drive can only be installed in one position on the oil pump drive shaft -arrow-.

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

–  Fit chain tensioner on oil pump drive chain and tighten securing bolt -3- to 18 Nm. –  Prise tensioning spring -1- over bolt -2- using a screwdriver.   Note t  Observe marks -arrows-. t  The crankshaft must not turn. –  Secure chain sprocket -3- hand-tight using a new bolt.

–  Place timing chain -1- on crankshaft chain sprocket -4- and exhaust camshaft chain sprocket -3- and tighten sprocket -2- hand-tight using a new bolt.   Note t  Note direction of rotation marks on timing chain -1-. t  Ensure guide sleeve is installed between inlet camshaft and sprocket -2-.

The timing chain must lie on the guide rail -1- and the crankshaft chain sprocket -arrow-.

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

–  Tighten bolts -2- to 50 Nm (use counterhold -T10172-).   Note The bolts -2-are tightened fully by tightening a further 90°, once the timing has been checked.

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

–  Hold camshaft wheels with counterhold -T10172- and tighten bolts -2- a 1/4 turn (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 procedure.