Engine installed, cylinder head removed

WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 1999 Volkswagen Jetta, 1999 Volkswagen GTI, 1998 Volkswagen Jetta, 1998 Volkswagen GTI, and 1997 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Set crankshaft to Cylinder 1 TDC by turning crankshaft in direction of engine rotation using vibration damper securing bolt.

If Cylinder 1 is at TDC, it is possible to see a notch on the intermediate shaft sprockets -arrow-.

If the notch cannot be seen:

Turn crankshaft one full turn in direction of engine rotation.

Fig 1: Identifying Notch On Intermediate Shaft Sprockets

CAUTION: If the crankshaft is turned with the cylinder head removed, a 2nd technician should guide the double chain by hand to keep it from jamming.

Lock camshafts in position with camshaft jig 3268.

Fig 2: Locking Camshafts In Position With Camshaft Jig 3268
Prepare cylinder head gasket for assembly, and install cylinder head, See CYLINDER HEAD, INSTALLING .
Place guide rail on locating pin. Apply thread locking fluid "D6" to short securing bolt and tighten both bolts.
- Tightening torque: 20 Nm (15 ft lb)
Mount camshaft sprocket and double chain to camshaft for cylinders 2, 4 and 6 (short camshaft) and tighten by hand.
Install camshaft sprocket (together with sensor wheel for Camshaft Position (CMP) Sensor - G40-) and double chain on camshaft for cylinders 1, 3 and 5, and tighten by hand.

NOTE: Contact surface of timing chain and sender wheel must be dry when installing.

Oil head contact surface of bolts when installing.

Remove camshaft jig 3268.
Tighten securing bolts for camshaft sprockets.
- Tightening torque: 100 Nm (74 ft lb)

CAUTION: The camshaft jig 3268 must not be installed when tightening or loosening the sprockets.

NOTE: Counter-hold only by using a 24 mm open-end wrench on the camshaft -arrows-.

Fig 3: Identifying Counter-Hold Positions On Camshafts

Coat sealing surface of sealing flange with AMV 188 001 02 sealant.
Oil O-ring (Part II , item -11-) and insert in cam sprocket cover.
Install camshaft sprocket cover, insert all bolts and tighten lightly.
First tighten M8 securing bolt.
- Tightening torque: 25 Nm (18 ft lb)
Tighten M6 securing bolts.
- Tightening torque: 10 Nm (7 ft lb)
Install double chain tensioner and tighten.
- Tightening torque: 30 Nm (22 ft lb)

NOTE:

If the chain tensioner has been pulled apart, bleed chain tensioner before installing, see Bleeding double chain tensioner .
Rotate engine (crankshaft) only with chain tensioner installed, otherwise single or double chain will jump over sprockets!

Turn crankshaft two full turns in direction of engine rotation and check valve timing, see VALVE TIMING, CHECKING .