Work sequence

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With engine removed

Install roller chain and chain tensioner with tension bar:

Set and check position of crankshaft in relation to intermediate shaft.

Fig 1: Roller Chain, Sliding Rail, Sprockets, Chain Tensioner, Drive Gear And Thrust Washer Notches

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ground tooth of drive gear - B - must be aligned with bearing parting line (TDC cyl. 1).

Install bolt without collar for sliding rail - 2 - and tighten to 10 Nm.
Install sliding rail - 2 - with roller chain - 1 - and both sprockets - 3 - and - 4 - (note direction of travel of roller chain Locking vibration damper in position under Valve timing, setting (Installing timing chains) ).

Fig 2: Roller Chain, Sliding Rail, Sprockets, Chain Tensioner, Drive Gear And Thrust Washer Notches

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark on sprocket for roller chain - 4 - must be aligned with notches - C - or - D - on thrust washer.
Release stop teeth in chain tensioner with a small screwdriver - A -.
Press tension bar against chain tensioner and tighten chain tensioner to 10 Nm.

Fig 3: Vibration Damper Locked In Position With Counter Hold 3406

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lock vibration damper in position with counter hold 3406.

Fig 4: Roller Chain, Sliding Rail, Sprockets, Chain Tensioner, Drive Gear And Thrust Washer Notches

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten sprockets 3 and 4 for intermediate shaft to 100 Nm.
Remove counter hold 3406.
Check position of crankshaft in relation to intermediate shaft.

Ground tooth of drive gear - B - must be aligned with bearing parting line (TDC cyl. 1).

Install camshaft roller chain and chain tensioner with tension bar:

Set both camshafts to TDC cyl. 1.

Fig 5: Camshaft Guide 3268 Insert Into Shaft Slot

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align camshafts with camshaft guide 3268.
Install bearing bolt for tension bar and tighten to 18 Nm.
Install tension bar for chain tensioner (camshaft roller chain).
Install bearing bolt with collar for sliding rail and tighten to 10 Nm.

NOTE:

If the cylinder head is removed:
Install cylinder head, refer to Cylinder head, removing and installing

Push sliding rail onto bearing bolt. Insert short mounting screw with locking compound D 000 600 and tighten both bolts to 20 Nm.

Fig 6: Marking roller chains

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place camshaft roller chain on intermediate shaft (note direction of travel).
Mount camshaft sprocket and roller chain on camshaft for cylinder bank 1, 3 and 5 (long camshaft) and counter tighten by hand.
Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4, and 6 and tighten by hand.

NOTE:

Coat contact surfaces of the bolt heads with oil when installing.

Remove camshaft guide 3268.
Tighten mounting bolts for camshaft sprockets to 100 Nm.

Fig 7: Identifying Camshaft Installed

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Hold camshaft - arrow - only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets.

Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten mounting bolt to 10 Nm.
Replace oil seal for sealing flange, refer to Sealing flange and flywheel/drive plate, removing and installing .
Prepare cylinder head gasket for assembly Preparing cylinder head gasket for installation under Cylinder head, removal and installation overview
Coat sealing surface of cover piece with AMV 188 001 02 .

Coat O-ring for oil passage seal and insert in cover piece.
Install cover piece, insert all mounting bolts and turn in opposite direction slightly.
Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm.
Install chain tensioner for camshaft roller chain and tighten to 40 Nm.

NOTE:

Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip.

Rotate crankshaft two turns in direction of rotation of engine and check valve timing, refer to Valve timing, checking .