How to Replace timing chain on VW Golf 4 2.3 and 2.3 4Motion

Special tools

• Camshaft locking tool – No.3268 or T10068.
• Crankshaft pulley holding tool – No.3273/3406 or 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] , [2] or [3] .
  

  NOTE: Ground tooth on crankshaft sprocket aligned with rear main bearing joint [3] .

• Ensure intermediate shaft sprocket timing marks aligned [4] .
• Fit locking tool to camshafts [5] . Tool No.3268.
• Remove tensioner(s) to ease timing chain removal/installation.
• During cylinder head repairs, with engine installed:
  • Engine positioned correctly at TDC on No.1 cylinder [1] or [2] when slot on intermediate shaft sprocket visible [6] .
  • If slot not visible, turn crankshaft one turn.
• Camshaft on early engines driven by duplex timing chain, tensioner MUST be bled before installation [7] :
  • Push 0,8 mm wire through oil drilling up to ball valve [8] .
  • Compress plunger into housing onto stop [9] .
  • If plunger moves out again, repeat bleeding procedure.
• Camshaft on later engines driven by simplex timing chain:NOTE: All V5 engines have simplex timing chain.
  • Tensioner has no oil drilling [10] .

  NOTE: If replaced, ensure correct tensioner fitted.

  • Tensioner MUST NOT be bled.
• Lubricate camshaft sprocket bolt mating face during assembly.
• Camshaft rotation can be prevented using 24 mm spanner at positions shown [11] .NOTE: DO NOT use camshaft locking tool [5] to prevent camshaft rotation.
• Install tensioner(s) after timing chain installation.
• After installation, reset lower timing chain tensioner:
  • Release locking mechanism [12] . Use screwdriver.
  • Push chain tensioner [13] against tensioner guide [14] .
  • Tighten tensioner bolts [15] . Tightening torque: 10 Nm.

NOTE: Crankshaft pulley bolt MUST only be used once.