Installing With Engine Removed

Timing chains, installing

With Engine Removed




- check position of crankshaft with reference to intermediate shaft
- ground tooth of drive gear B must align with bearing split, re-position if necessary
- install guide rail 2
- install chain 1 and intermediate shaft gears 3 and 4
- note direction of chain rotation
- marking on intermediate shaft 4 must align with notch C or D on the thrust washer
- unlatch lock gear in chain tensioner using a small screwdriver A
- this relaxes the chain tensioner providing additional play for chain routing
- tighten intermediate; shaft gears 3 and 4
- tighten to 100 Nm (74ft lb)




To prevent the engine from turning while tightening the shaft gears (Manual transmission):
- fasten flywheel/driving plate to the crankshaft with at least 3 bolts and lock in place with holding tool VW 558

To prevent the engine from turning while tightening the shaft gears (Automatic transmission):
- fasten drive plate to engine using holding tool VW 558
- use an M8 x 45 bolt
- place 2 M1O hex nuts between the holding tool and the drive plate




- position the camshafts in the cylinder head using the 3268 camshaft guide
- with the cylinder head removed
- install cylinder head, Service and Repair
- install tensioning rail for chain tensioner
- dual roller-chain
- position rail on both bearing bolt and cylinder head
- position dual roller chain on intermediate shaft gear
- note previously marked run direction
- attach camshaft chain gear and dual roller chain to the shorter camshaft (cylinders 2, 4 and 6) using distributor connector and hand tighten
- attach camshaft chain gear and dual roller chain to the longer camshaft (cylinders 1, 3 and 5) and hand tighten
- remove 3268 camshaft guide
- tighten camshaft chain gears
- tightening torque: 100 Nm (74 ft lb)




- use a 24mm wrench on hexes (arrows) to prevent camshaft rotation while torquing drive gears

CAUTION! DO NOT have the 3268 camshaft guide installed while tightening the camshaft gears.

- coat flange sealing surface with AMV 18800102 and install
- prepare cylinder head gasket for installation
- coat valve cover sealing surface with AMV 18800102 and insert sealing ring
- install front camshaft cover
- tighten chain tensioner
- rotate crankshaft two full turns in direction of engine rotation and stop when in cylinder 1 TDC position

CAUTION! DO NOT rotate the engine unless the chain tensioner is tightened; otherwise, the control chain will jump out.




- install and align 3268 camshaft guide onto cylinder head studs with both camshafts snugly positioned in the guide indentations (as shown)
- this alignment is only possible every 2nd engine revolution