How to Replace timing chain on VW Golf 4 3.2 R32 4Motion

Special tools

• Camshaft locking tool – No.T10068A.
• 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

NOTE: If reusing timing chains: Mark direction of rotation on chains.

• Removal/installation of timing chain requires:
  • Engine removal.
  • Transmission removal.
• 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] .
• If camshaft locking tool cannot be installed, turn crankshaft 360°.
• Remove tensioner(s) to ease timing chain removal/installation.

NOTE: If replaced, ensure correct tensioner fitted.

• Reset lower timing chain tensioner:
  • Release locking mechanism [5] . Use screwdriver.
  • Push tensioner rail [6] against chain tensioner [7] .NOTE: Lower timing chain tensioner bolts [8] MUST only be used once.
  • Tighten tensioner bolts [8] . Tightening torque: 8 Nm.

NOTE: Renew intermediate shaft sprocket bolt.

• Set inlet camshaft adjuster as follows:
  • Turn inlet camshaft position (CMP) sensor reluctor fully clockwise as far as stop [9] .
• Fit inlet camshaft sprocket with chain. Align sprocket with hole in camshaft [10] .
• Tighten inlet camshaft adjuster bolt finger tight.

NOTE: Inlet camshaft adjuster marked 24E.

• Set exhaust camshaft adjuster as follows:
  • Turn exhaust camshaft position (CMP) sensor reluctor fully clockwise as far as stop [9] .
• Fit exhaust camshaft sprocket with chain. Align sprocket with hole in camshaft [11] .
• Tighten exhaust camshaft sprocket bolt finger tight.

NOTE: Exhaust camshaft adjuster marked 32A.

• Ensure camshaft timing marks aligned [12] .

NOTE: Ground tooth on camshaft sprockets [13] aligned with timing marks on camshaft support bracket [12] .

• Ensure 8 links between ground tooth on each camshaft sprocket [12] .

NOTE: Fit new camshaft sprocket bolts.

• Install tensioner after timing chain installation.
• Turn the crankshaft two turns clockwise to No.1 cylinder at TDC [1] .
• Fit locking tool to camshafts [4] .
• Ensure timing marks aligned [12] .
• If not: Repeat timing chain installation.
• Tighten bolt of each camshaft sprocket to 60 Nm + 90° [14] .
• Camshaft rotation can be prevented using 32 mm spanner at positions shown [15] .

NOTE: DO NOT use camshaft locking tool to prevent camshaft rotation [4] .