The VW Eurovan has a timing chain, as opposed to a timing belt, which is the component that connects the camshaft and crankshaft of an engine. If the chain is stretched or worn, the timing of the engine valves and cylinders is lost, and the engine will not run properly. Many times, when the engine is out of timing, you only need to adjust the chain and sprocket. But, after a certain level of wear and tear, it must be replaced.
Remove the engine components
Disconnect the negative battery cable.
Drain the oil and coolant.
Remove the front and side covers from the engine.
Make a note of whether the timing plate turns clockwise or counterclockwise.
Screw the M8x50 bolt into the hole in the belt tensioning roller, and tighten, so that the belt loosens, and remove it.
Remove the cylinder cover and the rest of the engine components, until you have access to the timing chain.
Removing the timing chain
Rotate the crankshaft, until piston number one is at center dead center.
Using a marker, mark the direction of the timing shaft.
Remove the camshaft chain tensioning roller, the eight mounting bolts and the front chain cover.
Disconnect the front exhaust pipe.
Check that the timing is at center dead center. You can do this by looking between the timing chain sprockets on the intermediate shaft to see if a groove is visible. If the groove is not visible, turn the crankshaft one more turn until you can see it.
Remove the crankshaft and timing chain adjusters, followed by the two screws under the crankshaft sprocket.
Separate the chain and adjusters, carefully setting the chain aside.
Install the new chain
Align the sprocket teeth with the bearing spacing at the center dead center of cylinder one.
Install the follower bolts, without the collar, and use the torque wrench to tighten them to 89 inch pounds (226.0 cm lbs).
Attach the new timing chain and intermediate shaft sprockets, making sure the direction is correct according to the mark you made in Step Two in the “Removing the Chain” section. The mark on the gear should match the notches in the drive shaft washer.
Tighten the intermediate shaft bolts of the gears by hand, and use a small screwdriver to release the pressure from the tensioner locking slots, so that you can press the guide against the tensioner.
Install the tensioner bolts, and tighten them with the torque wrench to 72 inch pounds (32.6 kg lbs).
Hold the camshaft adjuster with a socket wrench, and align the intermediate shaft sprockets. Tighten with torque wrench to 44 foot pounds (18.14 kg lb.). Plus 90 degrees.
Make sure the sprockets are properly aligned and that the number one cylinder is pointing to center dead center.
Insert the ruler into the camshaft splines, and run the chain between the tension track and the slide track.
Install the intake and exhaust camshaft adjuster. The exhaust sensor adjuster should be on “Stop” to the right. The “A” and “B” marks on the camshaft adjuster must match the “C” notch on the control box.
Tighten the new camshaft adjuster screws by hand. You can now remove the adjusting ruler.
To check the valve timing, turn the crankshaft two turns. If the timing is right, use the torque wrench to tighten the camshaft adjustment bolts to 44 ft. lbs. Plus 90 degrees.
Put oil in front cover o-ring, and put cover back on. Continue to coat the mating surfaces with sealant and hand-tighten the screws. Tighten the M6 bolts to 72 inch pounds (182.88 cm lb.) and the M8 bolts to 18 foot pounds (21.95 meter pounds).
Replace the camshaft chain tensioner roller, and tighten it to 30 foot pounds (9.14 meter pounds).
Rotate the crankshaft twice, and check the timing again. If the timing is correct, install the remaining components, and reconnect the battery. Make sure the fluids are full before driving the vehicle.
Tips
This process requires a lot of parts to be removed, so label and organize everything properly. If possible, place the bolts and screws where you removed them from, so you know how they should go back in and with what fasteners.
Warnings
Before draining the fluids and to avoid burns, make sure your car has cooled down for a few hours.