Installing Timing Chains
Installing timing chainsTools
Tools and materials
Note: The tools can be purchased from the VW Parts Service.
Note: Observe the most important working regulations and warning notes.
Information
Component information
Installing timing chains
Note: Install top timing chain (if re-used) in rolling direction (marking).
1. Check that the crankshaft is positioned at the TDC of cylinder 1. To do this, align the crankshaft marking with the marking on the cylinder block Crankshaft pulley marking to cylinder block.
2. Position intermediate shaft so that the sprocket markings -C and D- correspond to the lines on the underlying thrust washer.
Note: Install bottom timing chain (if re-used) in rolling direction (marking).
3. Position bottom timing chain. To do this, position the timing chain around the crankshaft drive gear and intermediate shaft sprocket in such a way that the timing chain runs straight through the guide rail -2- without play. Leave the side of the timing chain leading to the chain tensioner -A- loose.
4. Place sprocket -3- on the intermediate shaft gearwheel -4- and install hand-tight using a new fastening screw (M12 x 40).
Note: Unblock the locking teeth in the chain tensioner with a small screwdriver and press tensioning rail against the chain tensioner.
5. Move tensioned chain tensioner into installation position and secure. Tightening torque: 8 (6 ft-lb.) Nm
6. Block crankshaft using an arm bracket T10069 with the help of an assistant.
7. Tighten M12 x 40 fastening screw for intermediate shaft -14-. Tightening torque: 60 (44 ft-lb.) Nm and Torque angle: 90°
8. Turn both camshafts at the hexagon -Arrow- in such a way that the camshaft guide t10068-A- fits into the grooves of both camshafts.
9. Slide tensioning rail -8- onto the collarless bolts -9-.
Note: The top timing chain has two copper-colored and one yellow chain link. These must match the corresponding markings on the sprockets or camshaft adjusters. The markings on the components are definitive for setting the timing so that the timing can also be set without the colored chain links. The colored chain links serve only as support.
Note:
^ If the colored chain links are used for setting the timing, these will no longer be in the same position after you have turned the crankshaft to check it out and then checked the timing again.
^ Only the markings on the components are definitive.
10. Lay timing chain between camshafts and intermediate shaft. The yellow chain link must correspond to the marking on the intermediate shaft sprocket -2-. Guide the timing chain along the black guide rail and fit to the camshaft adjusters. Make sure that the copper-colored chain links correspond to the engraved arrows on the camshaft adjusters -1-. Guide the top timing chain at the guide rail side (guide rail shown fitted here) without play. Only leave the timing chain loose at the tensioning rail side -3- (chain tensioner side).
11. Check position of camshaft adjusters. The engraved arrows -A and B- on the camshaft adjusters must be aligned with the notches -Arrows- on the timing chain housing -C- and the copper-colored chain links. The distance between tooth -1- and tooth -2- of the camshaft adjusters must be exactly 16 rolls of the camshaft chain tensioner. Timing chain housings with two notches with the inscription MPI and FSI have been used since the middle of 2005. The marking MPI must be used for setting the timing on this 3.2-litre engine with suction-pipe injection.
12. Slide in black guide rail -1- and tighten with two fastening screws -Arrows-. Tightening torque: 23 (17 ft-lb.) Nm
13. Make sure the timing chain is only loose at the tensioning rail side -3-.
14. Remove camshaft guide.
Note:
^ If the colored chain links are used for setting the timing, these will no longer be in the same position after you have turned the crankshaft to check it out and then checked the timing again.
^ Only the markings on the components are definitive.
15. Press the tensioning rail by hand or with a light tap of a hammer on to the timing chain instead of the removed chain tensioner and get an assistant to help turn the crankshaft by four turns. Check the timing.
Subsequent work for installing timing chains
1. Install bottom chain case lid.
2. Install top chain case lid.
3. Check the timing using a standard chain tensioner.
4. Install cylinder head cover.
5. Install engine.