Drive chain for timing mechanism, removing and installing

Special tools, testers and auxiliary items required 

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Old oil collecting and extracting device V.A.G 1782

Fig 2: Securing Pin T40071

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Securing pin T40071

Removing 

Fig 3: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove quick-release fasteners - 1  - , remove screws - 2  - and remove noise insulation.
• Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
• Remove engine → Engine, removing .
• Separate engine and transmission → Engine and transmission, separating .

• Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand → Engine, securing to assembly stand .
• Remove clutch pressure plate →
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
  • 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
  .
• Remove dual-mass flywheel → Dual-mass flywheel, removing and installing .
• Remove cylinder head cover: Left → Left cylinder head cover, removing and installing  , right → Right cylinder head cover, removing and installing .

• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Remove oil filter housing → Oil filter housing, removing and installing .
• Remove lower timing chain cover → Lower timing chain cover, removing and installing .

• Remove camshaft timing chains → Camshaft timing chain, removing and installing .
• Remove chain for power take-off → Power take-off drive chain, removing and installing .

Fig 4: Pushing Drive Chain Tensioner Guide Rail In And Securing Chain Tensioner Using Locking Pin T40071

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Push drive chain tensioner guide rail in direction of - arrow  - and secure chain tensioner using Locking Pin T40071.
• Mark running direction of timing chain with paint.
• Remove bolts - 1  - and remove guide rail.
• Remove bolts - 2  - and - 3  - and remove sprocket with drive chain.

Installing 

Installation is in reverse order of removal, note the following:

Fig 5: Securing Crankshaft In TDC Position Using Crankshaft Holder 3242

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure crankshaft in TDC position using crankshaft holder 3242.

Fig 6: Pushing Drive Chain Tensioner Guide Rail In And Securing Chain Tensioner Using Locking Pin T40071

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• First, install left camshaft timing chain sprocket - 2  -.
• Install guide rail - 1  - with installed drive chain.
• Now install right camshaft timing chain sprocket - 3  -.
• Press drive chain tensioner guide rail in direction of - arrow  - and pull securing pin T40071 out of the chain tensioner.

• Install chain for power take-off → Power take-off drive chain, removing and installing .
• Install camshaft timing chains Installing .
• Install lower timing chain cover → Lower timing chain cover, removing and installing .
• Install crankshaft seal, timing chain side → Crankshaft seal (timing chain side), replacing .

• Install oil filter housing → Oil filter housing, removing and installing .
• Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Install cylinder head cover: Left → Left cylinder head cover, removing and installing  , right → Right cylinder head cover, removing and installing .

• Install dual-mass flywheel → Dual-mass flywheel, removing and installing .
• Install clutch pressure plate →
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
  • 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
  .
• Install engine → Engine, installing .
• Add engine oil and check oil level → Oil level, checking .

Torque specifications