How to Replace timing chain on VW Passat 3C 3.6 FSI R36 4Motion

Special tools

• Camshaft locking tool – No.T10068A.
• Crankshaft pulley holding tool – No.T10172.
• Crankshaft pulley holding tool adapter – No.T10172/2.
• High-pressure fuel pump sprocket locking tool – No.T10363.

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:
  • Flywheel removal.
  • Sump 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 camshaft lobes for No.1 cylinder are positioned as shown [3] . If not, turn crankshaft 360°.
• Fit camshaft locking tool [4] .
• Ensure intermediate shaft sprocket timing marks aligned [5] .
• Remove tensioner(s) to ease timing chain removal/installation.

NOTE: If replaced, ensure correct tensioner fitted.

• Reset lower timing chain tensioner:
  • Release locking mechanism [6] . Use screwdriver.
  • Push tensioner rail against chain tensioner [7] & [8] .
  • Tighten tensioner bolts [9] . Tightening torque: 8 Nm.

NOTE: Renew intermediate shaft sprocket bolt.

• Tighten intermediate shaft sprocket bolt. Tightening torque: 60 Nm + 90°.
• Ensure high-pressure fuel pump sprocket timing mark at 12 o’clock position [10] .
• Fit high-pressure fuel pump sprocket locking tool [11] .
• Set inlet camshaft position actuator as follows:
  • Turn inlet camshaft position (CMP) sensor reluctor in both directions until locked [12] .
• Fit inlet camshaft sprocket with chain. Align sprocket with hole in camshaft [13] .
• Tighten inlet camshaft position actuator bolt finger tight.

NOTE: Inlet camshaft position actuator marked 24E.

• Set exhaust camshaft position actuator as follows:
  • Turn exhaust camshaft position (CMP) sensor reluctor in both directions until locked [12] .
• Fit exhaust camshaft sprocket with chain. Align sprocket with hole in camshaft [14] .
• Tighten exhaust camshaft sprocket bolt finger tight.

NOTE: Exhaust camshaft sprocket marked 32A.

• Ensure timing marks on both camshaft adjusters and on camshaft carrier aligned [15] & [16] .
• Ensure 8 links between timing marks on camshaft sprockets [17] .

NOTE: Fit new camshaft sprocket bolts.

• Install tensioner after timing chain installation.
• Remove high-pressure fuel pump sprocket locking tool [11] .
• Remove camshaft locking tool [4] .
• Turn the crankshaft two turns clockwise to No.1 cylinder at TDC [1] .
• Fit locking tool to camshafts [4] .
• Ensure timing marks aligned [15] & [16] .
• If not: Repeat timing chain installation.
• Camshaft rotation can be prevented using 27 mm spanner on hexagon.
• Tighten bolt of each camshaft sprocket to 60 Nm + 90° [18] .

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