Engine Removed
VALVE TIMING, ADJUSTING (TIMING CHAINS, INSTALLING)
Tools Needed:
- VW 558, counter-holding tool
- 3268, camshaft fixture
Single Chain With Chain Tensioner And Tensioning Plate, Installing:
- Check or adjust positioning of crankshaft to intermediate shaft. Ground-down tooth on crankshaft sprocket -B- must align with main bearing joint (TDC for No.1 cylinder).
- Install pin without collar for guide rail -2- and tighten to 25 Nm (18 ft lb).
- Install guide rail -2- with single chain -1- and both sprockets -3- and -4- (note direction of single chain, Fig. 1.) refer to "Engine, Disassembly and Assembly/GROUP I". Service and Repair
Marking on single chain sprocket -4- must align with notch -C- or -D- on thrust washer.
- Release locking spline in chain tensioner -A- with small screw driver.
- Press chain tensioner against tensioner guide and tighten tensioner to 10 Nm (7 ft lb).
Vehicles With Manual Transmission
- Tighten flywheel to crankshaft with 3 old bolts and counter-hold with VW 558.
Vehicles With Automatic Transmission
- Tighten drive plate to crankshaft with 3 old bolts and counter-hold with VW 558.
- Install counter-hold tool VW 558 to drive plate with M 8 X 45 bolt. Place two M 10 nuts between tool and drive plate.
All Vehicles
- Tighten intermediate shaft sprockets -3- and -4- see Fig. V13-1052 above. Torque 100 Nm (74 ft lb).
- Remove flywheel or drive plate and check position of crankshaft in relation to intermediate shaft
Double Chain And Chain Tensioner With Tensioning Plate, Installing:
- Locate camshafts with camshaft fixture 3268.
- Install tensioning plate pivot pins and tighten to 25 Nm (18 ft lb).
- Install tensioning plate for chain tensioner (double chain).
- Install locating pin with collar form guide rail and tighten to 25 Nm (18 ft lb).
With Cylinder Head Removed:
NOTE: Contact surfaces at timing chain and sensor wheel must be dry when installing. Oil contact surfaces of bolts when installing.
- Refer to cylinder head, installing.
- Install guide rail to pivot bolts. Insert short bolt with thread liquid D6 and tighten both bolts to 20 Nm (14 ft lb).
- Place double chain on intermediate shaft. Note turning direction of chain see Fig. 1 refer to "Engine, Disassembly and Assembly/GROUP I". Service and Repair
- Install camshaft sprocket and double chain to camshaft for cylinders 2, 4, and 6 (short camshaft) and hand tighten.
- Install camshaft sprocket and double chain to camshaft for cylinders 1, 3 and 5 and hand tighten.
- Remove camshaft fixture 3268.
- Tighten bolts for camshaft sprocket to 100 Nm (74ft lb).
NOTE: Only counter-hold with 24 mm open end wrench (arrow). Do not use camshaft fixture 3268 when tightening or loosening sprockets.
- Coat sealing surfaces of sealing flange with AMV 188 001 02 and install. Tighten bolt to 10 Nm (7 ft lb).
- Replace sealing flange oil seal.
- Prepare cylinder head gasket for installation see Fig 2 in "Cylinder Head, Component Overview". Service and Repair
- Coat sealing surfaces of camshaft cover with AMV 183 001 02.
- Lubricate 0-Ring with oil and insert in camshaft sprocket cover.
- Install camshaft sprocket cover, insert all bolts and tighten slightly.
- First tighten M 8 bolt to 25 Nm (18 ft lb), then M6 bolts to 10 Nm (7 ft lb).
- Install chain tensioner for double chain and tighten to 30 Nm (22 ft lb).
NOTE: If chain tensioner was pulled apart, bleed chain tensioner before installing see Fig. 2 in "Engine, Disassembly and Assembly/GROUP I". Service and Repair
CAUTION: Only turn engine with chain tensioner installed, otherwise single or double chain will jump.
- Turn crankshaft two full turns in running direction and check valve timing refer to "Valve Timing, Checking". Testing and Inspection