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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

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

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] .

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