VW Passat & Audi A4 1990-2000

Timing Chain & Gears

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REMOVAL & INSTALLATION
1993-97 Passat Models
2.8L VR6 Engine

The timing chains and gears are located beneath a housing on the flywheel side of the engine. To access the timing chain and gears the engine and transaxle assembly must be removed, then the transaxle and engine flywheel or drive plate and timing chain housing are removed.

  1. Remove the engine and transaxle assembly from the vehicle.
  2.  
  3. Separate the transaxle from the engine. For additional information, please refer to the following topic(s): Drive Train, Manual Transaxle, Automatic Transaxle.
  4.  
  5. Remove the flywheel or drive plate.
  6.  
  7. Remove the double chain tensioner from the upper chain housing.
  8.  
  9. Remove the upper and lower chain housing cover fasteners and remove.
  10.  
  11. Position the crankshaft to Top Dead Center (TDC) for cylinder No. 1.
  12.  
  13. Matchmark the direction of rotation of the chains with paint or suitable marker. Do NOT scratch the surface or use a punch.
  14.  
  15. Counter hold each camshaft using a 24 mm ( 15 / 16 s) open end wrench installed on the cast in hex portion of the camshaft. Loosen and remove both camshaft sprocket mounting bolts.
  16.  
  17. Remove the camshaft sprockets along with the Camshaft Position (CMP) Sensor wheel and remove from the double roller chain.
  18.  
  19. Loosen and remove the guide rail bolt.
  20.  
  21. Remove the tensioning plate for the double chain tensioner, then remove locating pin with the collar for guide rail.
  22.  
  23. Remove the tensioning plate pivot pins.
  24.  
  25. Remove the double roller chain along with the tensioning plate.
  26.  
  27. If equipped with a manual transmission, secure the flywheel to crankshaft with 3 used bolts, then counter-hold using Tool No. VW 558, or its equivalent.
  28.  
  29. If equipped with an automatic transmission, attach the drive plate to the crankshaft using 2 used bolts.
  30.  
  31. Use a M8 x 45 bolt to attach Tool No. VW 559, or its equivalent, to counter-hold the drive plate.
  32.  
  33. Loosen the intermediate shaft sprocket bolt.
  34.  
  35. Remove the lower right chain tensioner.
  36.  
  37. Remove the single chain along with the right side tensioner and both intermediate shaft sprockets making sure to note their Top Dead Center (TDC) alignment marks if not being replaced. During installation the marking on single chain sprocket must align with the top or bottom TDC notch on the thrust washer.
  38.  
  39. Remove the pin for the left side chain guide rail.
  40.  
  41. Remove the single row chain from the crankshaft drive gear along with the chain guide rail and tensioning plate. During reassembly, make sure the check the position of the crankshaft to the intermediate shaft. The ground down tooth on crankshaft sprocket must align with the left side main bearing cap-to-engine block seam. The engine must be at TDC for cylinder No. 1.
  42.  



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Fig. An exploded view of the VR6 timing chain, sprockets and related components



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Fig. Once the timing chain housing is removed the timing chain components are visible



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Fig. The Top Dead Center (TDC) marks illustrated on flywheel as they appear on automatic transmissions



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Fig. Use a 0.8 mm ( 1 / 32 inch) section of sturdy wire to press down the check ball and compress the piston into the housing. If the piston moves out again, repeat the procedure



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Fig. With the upper timing cover removed, when the engine is at Top Dead Center (TDC) the alignment notch of the intermediate shaft is visible



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Fig. The ends of the camshafts are slotted and held at Top Dead Center (TDC) with Alignment Tool No. 3268 or its equivalent

To Install :

  1. Position the crankshaft to Top Dead Center (TDC) for cylinder No. 1.
  2.  
  3. Install the single row chain onto the crankshaft drive gear along with the chain guide rail and tensioning plate. Make sure the check the position of the crankshaft to the intermediate shaft. The ground down tooth on crankshaft sprocket must align with the left side main bearing cap-to-engine block seam. The engine must be at TDC for cylinder No. 1.
  4.  
  5. Install the pin without the collar for the left side chain guide rail and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the single chain along with the right side tensioner and both intermediate shaft sprockets making sure to note their direction of rotation if not being replaced. The marking on single chain sprocket must align with the top or bottom TDC notch on the thrust washer.
  8.  
  9. Release the locking splines of the lower right chain tensioner using a small flat blade screw driver, then press the tensioner against the tensioning plate and tighten to 88 inch lbs. (10 Nm).
  10.  
  11. If equipped with a manual transmission, secure the flywheel to crankshaft with 3 used bolts, then counter-hold using Tool No. VW 558, or its equivalent.
  12.  
  13. If equipped with an automatic transmission, attach the drive plate to the crankshaft using 2 used bolts.
  14.  
  15. Use a M8 x 45 bolt to attach Tool No. VW 559, or its equivalent, to counter-hold the drive plate.
  16.  
  17. Tighten the intermediate shaft sprocket bolt to 74 ft. lbs. (100 Nm).
  18.  
  19. Remove the flywheel or drive plate and verify the position of crankshaft to the intermediate shaft.
  20.  
  21. Proper alignment must be achieved. If necessary repeat the previous procedures to obtain proper alignment.
  22.  
  23. Install the double roller chain along with the tensioning plate and tensioner.
  24.  
  25. Place the camshafts at TDC for cylinder No.1. The valves should be closed and the toe of the cam pointing upward away from the hydraulic lifters. If the camshafts must be moved and the lower cover and double roller chain installed, support the double roller chain using and an assistant if necessary. Rotate the engine away (opposite direction of operation) from TDC about 45-90°, then carefully turn the camshafts making sure the valves Do NOT collide until properly positioned. Once properly positioned carefully rotate the crankshaft to TDC.
  26.  


NOTE
If the crankshaft is correctly positioned, the TDC alignment notch on the intermediate shaft should be at the top most position.

  1. Install the camshaft alignment plate, Tool No. 3268, or its equivalent.
  2.  
  3. Install the tensioning plate pivot pins and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the tensioning plate for the double chain tensioner, then install locating pin with the collar for guide rail and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Place the guide rail on the locating pin, then insert the short securing bolt using a locking agent and tighten both bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. If removed, install the double chain onto the intermediate shaft gear making sure if not replaced, the chain is installed in its original direction of rotation.
  10.  
  11. Fit the camshaft sprocket and the double chain to the camshaft for cylinder Nos. 2, 4 and 6 (the shorter camshaft) and hand tighten the sprocket bolt.
  12.  
  13. Install the camshaft sprocket along with the Camshaft Position (CMP) Sensor wheel and the double roller chain onto the camshaft for cylinder Nos. 1, 3 and 5 and hand tighten.
  14.  


NOTE
Make sure that the contact surfaces of the timing chain and sensor wheel are dry when installing and to oil the contact surfaces of bolts during installation.

  1. Remove the camshaft alignment tool.
  2.  
  3. Counter hold each camshaft using a 24 mm ( 15 / 16 inch) open end wrench installed on the cast in hex portion of the camshaft. Tighten both camshaft sprocket mounting bolts to 74 ft. lbs. (100 Nm).
  4.  


WARNING
The camshaft alignment tool must not be installed when tightening or loosening the sprocket bolts.

  1. Install a new oil seal into the lower timing chain housing.
  2.  
  3. Whether replaced or not, coat the inner sealing lip of the seal and crankshaft oil seal journal with petroleum jelly or a light coating of fresh engine oil.
  4.  
  5. Clean and coat the sealing surfaces of the lower timing chain cover housing with a sealant, such as Part No. AMV 188 001 02, and install.
  6.  
  7. Tighten the M6 bolts lightly.
  8.  
  9. Clean and coat sealing surfaces of the upper timing chain cover housing with a proper sealant.
  10.  
  11. Install the cover onto the engine using new O-rings, coating the smaller O-ring with a light film of fresh engine oil. Lightly tighten the mounting bolts.
  12.  
  13. Tighten all the M8 upper and lower cover bolts to 18 ft. lbs. (25 Nm), then tighten the M6 bolts to 88 inch lbs. (10 Nm).
  14.  
  15. If the chain tensioner has pulled apart, bleed chain tensioner using a small, sturdy wire to relieve the check ball and collapse the tensioner. If the tensioner expands again, repeat the procedure.
  16.  
  17. Install the double chain tensioner into the housing with a new seal and tighten to 22 ft. lbs. (30 Nm).
  18.  
  19. Turn the crankshaft carefully two full revolutions in the normal running direction and verify the valve timing before attempting to start or before engine installation.
  20.  
  21. Install the flywheel or drive plate using new fasteners and torque as follows:
  22.  
  23. Step 1: 44 ft. lbs. (60 Nm)
  24.  
  25. Step 2: 90° ( 1 / 4 ) turn
  26.  
  27. The balance of assembly is in reverse order of removal.
  28.  

 
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