Engine timing drive 2.3-I-VR5 (VW Golf 4)

1 - camshaft sprocket;
2 - pulse rotor for Hall sensor;
3 - camshaft sprocket mounting bolt, 100 Nm. Before screwing in the bolt, lubricate the lower surface of the bolt head with a thin layer of engine oil. When tightening the bolt, hold the camshaft from turning with a SW 24 wrench;
4 - pivot pin, 18 Nm;
5 - O-ring. If damaged, use a new O-ring;
6 - chain tensioner, 40 Nm;
7 - tensioner bar;
8 - drive chain sprocket;
9 - Double-row sleeve roller chain. Before removing the chain, mark the direction of rotation of the chain;
10 - bolt, 100 Nm;
11 - drive chain sprocket;
12 - bolt, 10 Nm;
13 - chain tensioner with bar. Before removing the chain tensioner, use a screwdriver to release the locking toothed engagement and separate the chain guide from the tensioner. The engine can only be turned with the chain tensioner installed;
14 - chain drive sprocket. In the TDC position of piston 1 of cylinder, the cut tooth should be in line with the connector of the main bearing cap No.1;
15 - Single-row roller chain. Before removing the chain, mark the direction of rotation of the chain;
16 - damper bar;
17 - Stud for damper bar, 10 Nm;
18 - guide pin with flange, 10 Nm;
19 - bolt, 20 Nm. The bolt is installed using a special tool VW-D6;
20 - bolt, 20 Nm;
21 - damper bar;
22 - bolt, 20 Nm. The bolt is installed using a special tool VW-D6;
23 - adjusting washer;
24 - intermediate shaft

The arrangement of the elements of the gas distribution mechanism when the piston of the first cylinder is installed at the top dead center in the compression stroke

1 - chain;
2 - chain guide;
3 - front sprocket of the intermediate shaft;
4 - rear sprocket of the intermediate shaft;
A - chain tensioner mechanism lock;
B - the installation tooth on the crankshaft sprocket must be in line with the connector of the main bearing cap No.1;
C - timing mark on the intermediate shaft sprocket;
D - timing mark on the intermediate shaft sprocket

Places to apply marks before removing the timing chains

Before removing the timing chains, use paint to mark the chains in the locations shown in the illustration.

The camshafts are driven from the crankshaft, not directly, but through an intermediate sprocket. A smaller diameter sprocket is fixed on the same shaft as the intermediate sprocket, through which the second chain is driven by the valve timing mechanism. The upper chain of the camshaft drive is tensioned by a plate tensioner, which is held in the required position by an externally located adjusting bolt. The lower chain of the valve timing mechanism drive has a hydraulic tensioner, which does not require adjustment.

Removal

1. Turn the engine crankshaft to a position where the piston of the first cylinder is at the top dead center. In this case, the installation mark (indicated by the arrow) on the crankshaft pulley/vibration damper must be aligned with the pointer on the chain cover.

2. When the piston of the first cylinder is set to TDC, a groove should be visible on the sprockets of the intermediate shaft (indicated by the arrow). If the groove on the intermediate shaft sprocket is not visible, rotate the engine crankshaft one full revolution and re-align the timing marks with the pointers.