How to Replace timing chain on VW Golf 4 2.8 4Motion

Special tools

• Camshaft adjuster tool – No.T10067.
• Camshaft locking tool – No.T10068.
• Crankshaft pulley holding tool – No.T10069.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Timing chains located at rear of engine. Transmission removal required for repairs.
• Engine at TDC on No.1 cylinder [1] .
  

  NOTE: Ground tooth on crankshaft sprocket aligned with rear main bearing joint [2] .

• Ensure intermediate shaft sprocket timing marks aligned [3] .
• Fit locking tool to camshafts [4] . Tool No.T10068.
• Ensure there are 20 chain link pins [5] located between the timing marks on both camshaft sprockets [6] .
• During cylinder head repairs, with engine installed:
  • Engine positioned correctly at TDC on No.1 cylinder [1] when slot on intermediate shaft sprocket visible [7] .
  • If slot not visible, turn crankshaft one turn.
• Remove tensioner(s) to ease timing chain removal/installation.
• Before removing camshaft adjuster, install and hand tighten tool [8] . Tool No.T10067.NOTE: DO NOT overtighten tool.

NOTE: Bolts for camshaft sprockets and auxiliary shaft sprockets MUST only be used once [9] & [10] .

• During assembly, ensure mating faces between camshaft sprockets and camshaft sprocket bolts are kept dry.
• Camshaft rotation can be prevented using 32 mm spanner at positions shown [11] .NOTE: DO NOT use camshaft locking tool [4] to prevent camshaft rotation.
• Reset lower timing chain tensioner before installation:
  • Release locking mechanism [12] . Use screwdriver.
  • Push chain tensioner [13] against tensioner guide [14] .
• Install tensioner(s) after timing chain installation.
  • Upper chain tensioner [15] . Tightening torque: 40 Nm.
  • Lower chain tensioner bolts [16] . Tightening torque: 8 Nm.

NOTE: Crankshaft pulley bolt MUST only be used once [17] .