Camshaft timing chain, removing and installing: Installing

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Secure crankshaft in TDC position using Crankshaft Holder 3242.
Drive chain for timing mechanism installed → Drive chain for timing mechanism, removing and installing .

NOTE:

Always replace bolts that are tightened to torque as well as O-rings and gaskets.
When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.

Fig 1: Rotating Inner Part And Outer Part Of Both Camshaft Adjusters Against Each Other Up To Lock Position

GW00018193

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rotate inner part and outer part of both camshaft adjusters against each other up to lock position - arrows -.

Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt).

Check whether camshafts of both cylinder heads stand in TDC position.

Fig 2: Identifying Slits At Front In Camshafts Stand Parallel At Same Height With Upper Edge Of Cylinder Head

GW00018186

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Fig 3: Removing/Installing Camshaft Locator T40046

GW00018187

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert camshaft locator T40046 into camshafts of left cylinder head, to do so rotate camshafts back or forth at hex head if necessary.

Fig 4: Removing/Inserting Camshaft Locator T40046 From/Into Camshafts Of Right Cylinder Head

GW00018194

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert camshaft locator T40046 into camshafts of right cylinder head, to do so rotate camshafts back or forth at hex head if necessary.
Replace all four camshaft bolts.
Replace diamond disc between camshaft and left cylinder head camshaft adjuster.
Assemble left timing chain with chain sprocket and camshaft adjuster.

Fig 5: Removing Bolts For Camshaft Chain Sprocket Or Camshaft Adjuster Using Multipoint Socket T10035

GW00018190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosely install bolts - 1 - and - 2 -.

Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

Replace diamond disc between camshafts and right cylinder head camshaft adjuster.
Assemble right timing chain with chain sprocket and camshaft adjuster.

Fig 6: Removing Bolts For Camshaft Chain Sprocket Or Camshaft Adjuster Using Multipoint Socket T10035

GW00018192

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosely install bolts - 1 - and - 2 -.

Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

Fig 7: Removing/Installing Crankshaft Holder 3242 Into Hole

GW00018188

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove Crankshaft Holder 3242.

Fig 8: Using Key T40049 To Rotate Crankshaft In Opposite Direction Of Engine Rotation

GW00018195

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using key T40049 , rotate crankshaft approx. 30 ° in opposite direction of engine rotation - arrow -.
Pull drill bit out of alignment hole, which loosens left chain tensioner.

Fig 9: Inserting Trim Removal Wedge 3409

GW00018196

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Lightly pressing in an extra 0.5 mm is permitted.

Pull drill bit out of alignment hole, which loosens right chain tensioner.

Fig 10: Insert Trim Removal Wedge 3409

GW00018197

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Lightly pressing in an extra 0.5 mm is permitted.

Fig 11: Rotating Crankshaft To TDC Ignition Timing

GW00018185

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using key T40049 , rotate crankshaft in direction of engine rotation - arrow - to TD ignition timing.

NOTE:

If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30 ° and set to TDC again.

Fig 12: Removing/Installing Crankshaft Holder 3242 Into Hole

GW00018188

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Fig 13: Locating Camshaft Bolt On Exhaust Camshaft Of Left Cylinder Head

GW00018198

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening torque.

Torque specification: 40 Nm.

Fig 14: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Left Cylinder Head Using Setting Gauge T40047

GW00018199

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
Place setting gauge T40047 on bolt - 1 -.
Tighten camshaft bolt - 2 - on intake camshaft to initial tightening torque.

Torque specification: 40 Nm.

Fig 15: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Right Cylinder Head Using Setting Gauge T40047

GW00018200

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
Place setting gauge T40047 on bolt - 2 -.
Tighten camshaft bolt - 1 - on intake camshaft to initial tightening torque.

Torque specification: 40 Nm.

Remove setting gauge T40047.

Fig 16: Locating Camshaft Bolt On Exhaust Camshaft Of Right Cylinder Head

GW00018201

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening torque.

Torque specification: 40 Nm.

NOTE:

Camshaft locators T40046 must not be used as counter holder for final tightening of camshaft bolts.

Fig 17: Removing/Installing Camshaft Locator T40046

GW00018187

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove camshaft locators T40046 on both cylinder heads.

Fig 18: Locating Camshaft Bolt On Exhaust Camshaft Of Left Cylinder Head

GW00018198

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque.

Torque specification: 100 Nm plus an additional ¹ /₄ turn (90 °).

Fig 19: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Left Cylinder Head Using Setting Gauge T40047

GW00018199

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
Place setting gauge T40047 on bolt - 1 -.
Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque.

Torque specification: 100 Nm plus an additional ¹ /₄ turn (90 °).

Fig 20: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Right Cylinder Head Using Setting Gauge T40047

GW00018200

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
Place setting gauge T40047 on bolt - 2 -.
Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque.

Torque specification: 100 Nm plus an additional ¹ /₄ turn (90 °).

Remove setting gauge T40047.

Fig 21: Locating Camshaft Bolt On Exhaust Camshaft Of Right Cylinder Head

GW00018201

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque.

Torque specification: 100 Nm plus an additional ¹ /₄ turn (90 °).

Fig 22: Removing/Installing Crankshaft Holder 3242 Into Hole

GW00018188

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove Crankshaft Holder 3242.

Fig 23: Rotating Crankshaft To TDC Ignition Timing

GW00018185

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using key T40049 turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

Fig 24: Identifying Slits At Front In Camshafts Stand Parallel At Same Height With Upper Edge Of Cylinder Head

GW00018186

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Fig 25: Removing/Installing Crankshaft Holder 3242 Into Hole

GW00018188

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Fig 26: Removing/Installing Camshaft Locator T40046

GW00018187

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert camshaft locator T40046 into camshafts of left cylinder head.

Fig 27: Removing/Inserting Camshaft Locator T40046 From/Into Camshafts Of Right Cylinder Head

GW00018194

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert camshaft locator T40046 into camshafts of right cylinder head.

If camshaft locators cannot be inserted:

Repeat adjustment.
Pull out trim removal wedge 3409.
Remove camshaft locator T40046 on both cylinder heads.
Remove Crankshaft Holder 3242.

Install sealing plug of TDC marking with new sealing ring into upper section of oil pan.

The rest of installation is in reverse order of removal, note the following:

Install covers for timing chains Installing .
Install engine: Vehicles with manual transmission → Engine (vehicles with manual transmission), installing , vehicles with automatic transmission → Engine (vehicles with automatic transmission), installing .
Add engine oil and check oil level → Oil level, checking .