Volkswagen Cars 2000-05

Timing Belt, Cover & Seal 2

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Removal & Installation



4.0L (Bdp) Engines

NOTE
The following procedure is for cylinder bank no. 1. Cylinder bank no. 2 is similar.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove or disconnect:

    Upper intake manifold.
     

  14.  
  15. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  16.  
  17. Remove the ignition coils using T10094 extractor.
  18.  
  19. Remove or disconnect:
    NOTE
    Cover intake ports to prevent debris from entering.



    Cylinder head cover
     
    Fuel rail with injectors.
     
    Lower intake manifold spacer.
     



    Coolant pipes.
     
    Intake pipes.
     

  20.  
  21. Turn the crankshaft until no. 1 cylinder is at TDC. Mark on crankshaft damper must align with mark on cylinder block joint.
  22.  
  23. Remove the camshaft chain tensioner.
  24.  
  25. Remove the timing chain upper cover.
  26.  
  27. Remove the timing chain lower cover.
  28.  
  29. Mark the timing chain rotation direction for installation.
  30.  
  31. Remove the exhaust camshaft adjuster bolts.
  32.  
  33. Remove the intake camshaft adjuster bolts.
  34.  
  35. Remove the camshaft adjusters together with the timing chain.
  36.  
  37. Remove the timing chain guide rail.

    Click image to see an enlarged view

    Fig. Locating TDC alignment marks-4.0L engine

  38.  

To install:

  1. Set the crankshaft and camshafts to TDC for cylinder No. 1.
  2.  
  3. Secure the crankshaft from turning.
  4.  
  5. Install camshaft adjuster guide T10068 into horizontal slots on camshafts to lock them in place
  6.  
  7. On cylinder bank no. 1, install the timing chain as follows:
  8.  
  9. On the intake camshaft adjuster, turn the Hall sensor wheel clockwise to its stop.
  10.  
  11. On the exhaust camshaft adjuster, turn the Hall sensor wheel counterclockwise to its stop.
  12.  
  13. Install the timing chain and camshaft adjuster as a unit.
  14.  
  15. Copper link -A- of timing chain must be positioned on the top of the intermediate shaft.
  16.  
  17. Copper link of timing chain must align with -B1- arrow on intake camshaft adjuster
  18.  
  19. Copper link of timing chain must align with -B1- arrow on exhaust camshaft adjuster
  20.  
  21. Tighten NEW camshaft adjuster bolts hand tight.
  22.  
  23. Install the guide rail and tensioning rail.
  24.  
  25. On cylinder bank no. 2, install the timing chain as follows:
  26.  
  27. On the intake camshaft adjuster, turn the Hall sensor wheel clockwise to its stop.
  28.  
  29. On the exhaust camshaft adjuster, turn the Hall sensor wheel counterclockwise to its stop.
  30.  
  31. Install the timing chain and camshaft adjusters as a unit.
  32.  
  33. Copper link -A- of timing chain must be positioned on the top of the intermediate shaft.
  34.  
  35. Copper link of timing chain must align with -B2- arrow on intake camshaft adjuster
  36.  
  37. Copper link of timing chain must align with -B2- arrow on exhaust camshaft adjuster
  38.  
  39. Tighten NEW camshaft adjuster bolts hand tight.
  40.  
  41. Install the guide rail and tensioning rail.
  42.  
  43. Install the chain tensioner limit stop and tighten to 15 ft. lbs. (20 Nm).
  44.  
  45. Install the chain tensioner and tighten to 71 inch lbs. (10 Nm).
  46.  
  47. On both cylinder banks, proceed as follows:
  48.  
  49. Remove camshaft adjuster guide T10068 from both heads.
  50.  
  51. Hold crankshaft from turning and install NEW intermediate sprocket bolt and tighten to 44 ft. lbs. (60 Nm).
  52.  
  53. Hold camshafts in place with a 32 mm open end wrench, and tighten NEW camshaft adjuster bolts to 44 ft. lbs. (60 Nm).
  54.  
  55. Install lower timing chain cover and tighten bolts in sequence.
  56.  
  57. Install sealant to cylinder bank no. 1 upper timing belt cover and tighten bolts in sequence to 71 inch lbs. (10 Nm).
  58.  
  59. Install sealant to cylinder bank no. 2 upper timing belt cover and tighten bolts in sequence to 71 inch lbs. (10 Nm).
  60.  
  61. Replace the remaining components by reversing the removal procedures.
  62.  
  63. Reconnect the negative battery cable.
  64.  
  65. Test drive the vehicle.

    Click image to see an enlarged view

    Fig. Installing timing chain on cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on intake camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on exhaust camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Installing timing chain on cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on intake camshaft adjuster for cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on exhaust camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for upper timing chain cover for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for upper timing chain cover for cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for lower timing chain cover-4.0L engine

  66.  

 
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