VOLKSWAGEN
Corrado 2.8L VR6 AAA 1992-94
Golf/GTI 2.8L VR6 AAA 1995-99
Jetta 2.8L VR6 AAA 1994-99
Passat 2.8L VR6 AAA 1993-97
Special tools • During cylinder head repairs, with engine installed:
o Engine positioned correctly with NO.1 cylinder
• Camshaft locking tool - Volkswagen No.3268. at TDC of compression stroke D when slot
• Crankshaft pulley holding tool - on intermediate shaft sprocket is visible 1iJ.
Volkswagen NO.3273. o If slot is not visible, turn crankshaft one turn
• Flywheel/drive plate locking tool - clockwise.
Volkswagen No.vW558. • Camshaft tensioner MUST be bled before
installation [i):
General precautions o Push 0.031 in. diameter wire through oil
drilling up to ball valve 6.
• Disconnect battery ground cable. o Press plunger into housing onto stop Ill.
• Do NOT turn crankshaft or camshaft with o If plunger moves out again, repeat bleeding
timing chain removed. procedure.
• Remove spark plugs to ease turning engine.
• Lubricate camshaft sprocket bolt mating face
• Turn crankshaft in normal direction of rotation during assembly.
(unless otherwise stated).
NOTE: Mating surface between camshaft
• If required: Mark position of crankshaft position position (CMP) sensor reluctor and sprocket
(CKP) sensor before removal.
MUST be kept dry during assembly.
• Do NOT turn crankshaft via camshaft or other
sprockets. • Camshaft rotation can be prevented using
• Observe all tightening torques. 24 mm spanner at positions shown m.
NOTE: 00 NOT use camshaft locking tool B
to prevent camshaft rotation. .
Valve timing procedures
• If removed, apply locking fluid to upper timing
• Removal/installation of timing chain(s) requires: chain guide bolt [ll].
o Transmission removal. • Install tensioner(s) after timing chain installation.
NOTE: Timing chains located at rear of • After installation, reset lower timing chain
engine. tensioner:
• Engine NO.1 cylinder at TDC of compression o Release locking mechanism m using a
stroke D. screwdriver.
NOTE: Torque converter has 3 No.1 cylinder o Push chain tensioner IE against tensioner
TOC timing marks, verify by checking piston guide iE.
position. o Torque tensioner bolts 1m to 7 ft. Ibs.
• Ground tooth on crankshaft sprocket aligned • Torque upper timing chain tensioner [Ej:
with rear main bearing joint f). o (A) Golf/GTI/Jetta/Passat - 22 ft. Ibs.
• Ensure intermediate shaft sprocket timing marks
o (8) Corrado - 15 ft. Ibs.
aligned B. • After installation of timing chains:
• Fit locking tool NO.3268 to camshafts B.
o Turn crankshaft 2 turns clockwise until ground
tooth on crankshaft sprocket aligned with rear
• Remove tensioner(s) to ease timing chain main bearing joint f).
removal/installation. o Ensure camshaft locking tool NO.3268 can be
installed B.
• Crankshaft pulley bolt MUST only be used once.
_~ IIAutodata I
1m
(15 ft. Ibs.)
MT AD2.2"
VOLKSWAGEN
; Special tools • Engine No. -AES003278: Camshaft driven by
duplex timing chain, tensioner MUST be bled
• Camshaft locking tool - Volkswagen No.3268. before installationm:
• Crankshaft pulley holding tool - o Push 0.031 in. diameter wire through oil
Volkswagen NO.3406. drilling up to ball valve D.
o Press plunger into housing onto stop Ill.
'.General precautions o If plunger moves out again, repeat bleeding
procedure.
• Disconnect battery ground cable. • Engine No. AES003279 -: Camshaft driven by
• Do NOT turn crankshaft or camshaft with simplex timing chain:
timing chain removed.
o Tensioner has no oil drilling Ii] and cannot be
• Remove spark plugs to ease turning engine. bled.
• Turn crankshaft in normal direction of rotation NOTE: If replaced, ensure correct tensioner
(unless otherwise stated). is'fitted.
• If required: Mark position of crankshaft position
(CKP) sensor before removal. • Lubricate camshaft sprocket bolt mating face
• Do NOT turn crankshaft via camshaft or other during assembly.
sprockets. NOTE: Mating surface between camshaft
• Observe all tightening torques. position (CMP) sensor reluctor and sprocket
MUST be kept dry during assembly.
• Camshaft rotation can be prevented using
24 mm spanner at positions shown ml.
• Removal/installation of timing chain(s) requires: NOTE: DO NOT use camshaft locking tool 19
o Transmission removal. to prevent camshaft rotation.
NOTE: Timing chains located at rear of • If removed, apply locking fluid to upper timing
engine. chain guide bolt m.
• Engine NO.1 cylinder at TDC of compression • Install tensioner(s) after timing chain installation.
stroke D. • After installation, reset lower timing chain
• Ground tooth on crankshaft sprocket aligned tensioner:
with rear main bearing joint 18. o Release locking mechanism m using a
• Ensure intermediate shaft sprocket timing marks screwdriver.
aligned lB. o Push chain tensioner ~ against tensioner
• Fit locking tool No.3268 to camshafts 19. guide m.
• Remove tensioner(s) to ease timing chain
o Torque tensioner bolts IE! to 7 ft. Ibs.
removal/installation. • After installation of timing chains:
• During cylinder head repairs, with engine
o Turn crankshaft 2 turns clockwise until ground
tooth on crankshaft sprocket aligned with rear
installed:
main bearing joint 18.
o Engine positioned correctly with NO.1 cylinder o Ensure camshaft locking tool NO.3268 can be
at TDC of compression stroke D when slot installed 19.
on intermediate shaft sprocket visible 1;).
o If slot is not visible, turn crankshaft one turn • Crankshaft pulley bolt MUST only be used once.
clockwise.
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m
(15 ft. Ibs.)
I IAutodata I
VOLKSWAGEN
Golf/GTI 2.8L VR6 AFP 1999-01
Jetta 2.8L VR6 AFP 1999-01
Special tools • Lubricate camshaft sprocket bolt mating face
during assembly.
• Camshaft locking tool - Volkswagen NO.3268. NOTE: Mating surface between camshaft
• Crankshaft pulley holding tool - position (CMP) sensor reluctor and sprocket
Volkswagen NO.3406. MUST be kept dry during assembly.
• Camshaft rotation can be prevented using
General precautions 24 mm spanner at positions shown III
• Disconnect battery ground cable.
NOTE: DO NOT use camshaft locking tool 19
to prevent camshaft rotation.
• Do NOT turn crankshaft or camshaft with
timing chain removed. • If removed, apply locking fluid to upper timing
• Remove spark plugs to ease turning engine. chain guide bolt D.
• Turn crankshaft in normal direction of rotation • Install tensioner(s) after timing chain installation.
(unless otherwise stated). • After installation, reset lower timing chain
• If required: Mark position of crankshaft position tensioner:
(CKP) sensor before rernoval. o Release locking mechanism I1l using a
• Do NOT turn crankshaft via camshaft or other screwdriver.
sprockets. o Push chain tensioner III against tensioner
• Observe all tightening torques. guide ml.
o Torque tensioner bolts m to 7 ft. Ibs.
Valve timing procedures • After installation of timing chains:
o Turn crankshaft 2 turns clockwise until ground
• Removal/installation of timing chain(s) requires: tooth on crankshaft sprocket aligned with rear
o Transmission removal. main bearing joint fl.
NOTE: Timing chains located at rear of o Ensure camshaft locking tool can be
engine. installed 19.
• Engine NO.1 cylinder at TDC of compression • Crankshaft pulley bolt MUST only be used once.
stroke D.
• Ground tooth on crankshaft sprocket aligned
with rear main bearing joint fl.
• Ensure intermediate shaft sprocket timing marks
aligned B.
• Fit locking tool to camshafts 19.
• Remove tensioner(s) to ease timing chain
removal/installation.
• During cylinder head repairs, with engine
installed:
o Engine positioned correctly with NO.1cylinder
at TDC of compression stroke 0 when slot
on intermediate shaft sprocket visible 1:1.
o If slot is not visible, turn crankshaft one turn
clockwise.
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I IAutodata I
VOLKSWAGEN
Special tools • Remove tensioner(s) to ease timing chain(s)
removal/installation.
• Camshaft adjuster holding tool - NO.T40079. • Push plunger EJ into tensioner housing m and
• Camshaft locking tool x 2 - No.T40070. insert tensoiner locking pin m.
• Crankshaft locking pin - NO.3242. • Slacken central bolt of each LH cylinder head
• Crankshaft alignment tool - NO.T40058. camshaft adjuster 1 turn 6.
• Timing chain tensioner locking pin - NO.T40071. NOTE: Mark chain link and camshaft
• Torque wrench - NoVAG 1332. adjusters with paint before removal.
• Torque wrench adapter - NoVAG 1332/9.
• Align camshafts.
• Install camshaft locking tool to LH cylinder
General precautions bank B.
• Disconnect battery ground cable. • Install camshaft locking tool bolts. Torque to
• Do NOT turn crankshaft or camshaft with 15 ft. Ibs.
timing chain removed. • Pre-tension chain using camshaft adjuster
• Remove spark plugs to ease turning engine. pre-tensioning tools m.
• Turn engine in normal direction of rotation • Tighten bolt of each LH camshaft adjuster in two
(unless otherwise stated). stages:
• If required: Mark position of crankshaft position o Tighten LH inlet camshaft adjuster bolt to
(CKP) sensor before removal. stage A: 30 ft. Ibs.
• Do NOT turn crankshaft via camshaft or other o Maintain pre-tension on LH inlet camshaft
sprockets. adjuster m.
• Observe all tightening torques. o Tighten LH exhaust camshaft adjuster bolt to
stage A: 30 ft. Ibs.
Valve timing procedures o Remove camshaft adjuster pre-tensioning
tools m.
• Timing chains located at rear of engine. o Tighten bolt of each LH camshaft adjuster to
• Removal/installation of timing chain(s) requires: stage B: 59 ft. Ibs. + 90°.
o Transmission removal. • Repeat valve timing procedure for RH cylinder
o Flywheel removal. bank.
NOTE: All bolts with an angular torque • Remove timing chain tensioner locking pins after
setting MUST be replaced. repairs m.
• Turn crankshaft pulley clockwise until just before NOTE: Central bolt of camshaft adjusters
TDC on NO.1 cylinder. MUST only be used once.
• Remove blanking plug from cylinder block. • Remove crankshaft locking pin and camshaft
• Slowly turn crankshaft pulley clockwise until locking tool D & B.
crankshaft locking pin can be inserted in • Turn crankshaft two turns clockwise.
crankshaft D. • Fit crankshaft locking pin D.
• Ensure camshafts correctly aligned 6. • Check valve timing.
Threaded holes in camshafts point upwards. • Remove crankshaft locking pin D.
• Install camshaft locking tools B. Torque to • Refit blanking plug for cylinder block.
15 ft. Ibs. NOTE: If timing chains are to be reused,
• If camshaft locking tool cannot be installed valve mark LH and RH chains before removal to
timing is incorrect. ensure they are refitted in their original
positions.
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(7 ft. Ibs.)
(22 ft. Ibs. + 90°)
(7 ft. Ibs. + 90°)
(44 ft. Ibs.)
I/Aulodata I ~.
VOLKSWAGEN
Special tools
• Crankshaft pulley holding tool -
Volkswagen NO.3102/3149.
General precautions
• Disconnect battery ground cable.
• Do NOT turn crankshaft or camshaft with
timing gear(s) removed.
• Remove spark plugs to ease turning engine.
• Turn crankshaft in normal direction of rotation
(unless otherwise stated).
• If fitted: Mark position of crankshaft position
(CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other
gears.
• Observe all tightening torques.
• Removal/installation of timing gears requires:
o Engine removal.
• Align crankshaft gear timing mark (2 dots) with
camshaft gear timing mark (1 dot) D.
• Replace camshaft bearings if end play wear limit
of 0.006 in. is reached.
• Camshaft gear is an integral part of camshaft.
• Timing gear backlash MUST be between
0-0.002 in.
• To correct backlash, camshafts are available
with various size timing gears.
• Camshaft MUST NOT lift out of bearings when
crankshaft is turned counterclockwise. To
correct, install camshaft with a smaller diameter
timing gear.
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