Volkswagen Eurovan 2000-03

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove engine covers at the front of the engine compartment and underneath the vehicle.
  6.  
  7. Mark the rotation direction of the drive belt.
  8.  
  9. Insert an M8x50 bolt into the threaded hole of the belt tensioner roller and tighten just enough until tension is off belt and drive belt can be removed.
  10.  
  11. Remove the cylinder head cover.
  12.  
  13. Remove the necessary components to gain access to the front of the engine.
  14.  
  15. Place the crankshaft at TDC for no. 1 cylinder.
  16.  
  17. Mark the camshaft timing chain rotation direction with a paint mark.
  18.  
  19. Remove the camshaft roller chain tensioner.
  20.  
  21. Remove the 8 mounting bolts and remove the chain front cover
  22.  
  23. Disconnect the front exhaust pipe from the exhaust manifold.
  24.  
  25. Check that timing is at TDC by looking down between timing chain sprockets of the intermediate shaft. A groove should be visible between the chain edges.
  26.  


NOTE
If the groove cannot be seen, turn crankshaft one more revolution until groove can be seen.

  1. Insert camshaft gauge T10068 into both camshaft grooves.
  2.  


NOTE
If the gauge cannot be inserted, rotate crankshaft about .20 inches (5 mm) above TDC position until gauge can be inserted.


NOTE
Markings -A- and -B- on the camshaft adjusters must match the notches of control housing -C.-

  1. Remove the camshaft adjusters together with the timing chain from the camshafts.
  2.  
  3. Remove the two bolts from the glide track located at lower left below camshaft sprocket.
  4.  
  5. Remove the timing chain from the camshaft adjusters and place chain on its side.
  6.  


    Click image to see an enlarged view

    Fig. Lining up camshaft adjusters to remove timing chain-2.8L engine



    Click image to see an enlarged view

    Fig. Identifying TDC position on timing chain sprockets of intermediate shaft-2.8L engine



    Click image to see an enlarged view

    Fig. Identifying timing chain positioning on crankshaft and intermediate shaft sprockets-2.8L engine


To install:

  1. Adjust the milled tooth of the drive pinion to line up with the bearing separating gap at TDC on cylinder no. 1.
  2.  
  3. Install the glide track bolts, without the collar, and torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the timing chains and the intermediate shaft gears (if removed), ensuring that the timing chain rotation direction is correct.
  6.  
  7. Check that the marking on the gear matches with the notches on the intermediate shaft thrust washer.
  8.  
  9. Hand tighten the intermediate shaft gear bolts.
  10.  
  11. Use a small screwdriver to release the tension of the locking splines in the chain tensioner and press the tensioner track against the tensioner.
  12.  
  13. Install the timing chain tensioner bolts and torque to 72 inch lbs. (8 Nm).
  14.  
  15. Use a socket wrench to hold the crankshaft damper in position.
  16.  
  17. With the intermediate shaft sprockets lined up correctly, torque the bolts to 44 ft. lbs. (60 Nm), plus 90°.
  18.  
  19. Check that all sprockets are correctly lined up and cylinder no. 1 is at TDC.
  20.  
  21. Insert camshaft adjusting ruler tool T10068 into camshaft grooves.
  22.  
  23. Guide the timing chain between the tensioning track and the glide track.
  24.  
  25. Install the intake camshaft adjuster first with the timing chain installed, then install the exhaust camshaft adjuster.
  26.  


NOTE
Exhaust camshaft adjuster can be offset in two directions. When installing, make sure the camshaft position sensor is turned to stop in a clockwise direction. Distance between the milled teeth markings on the timing chain at the camshaft adjuster markings is exactly 16 rollers on the timing chain.


NOTE
Markings -A- and -B- on the camshaft adjusters must match the notches of control housing -C.-

  1. Hand tighten NEW bolts for camshaft adjusters.
  2.  
  3. Remove camshaft adjusting ruler T10068.
  4.  
  5. Rotate crankshaft 2 revolutions and recheck valve timing.
  6.  
  7. If valve timing is okay, secure camshafts in position and torque camshaft adjuster bolts to 44 ft. lbs. (60 Nm), plus 90°.
  8.  
  9. Place oil on the front cover O ring and install in cover.
  10.  
  11. Coat the front cover sealing surface with sealant and hand tighten the bolts.
  12.  
  13. Torque the front cover M6 bolts to 72 inch lbs. (8 Nm), and tighten the M8 bolts to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the camshaft roller chain tensioner and torque the bolts to 30 ft. lbs. (40 Nm).
  16.  
  17. Rotate crankshaft 2 revolutions and recheck valve timing.
  18.  
  19. Replace the remaining components by reversing the removal procedures.
  20.  
  21. Reconnect the negative battery cable.
  22.  
  23. Test drive the vehicle.
  24.  

 
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