Timing Belt: Service and Repair

Toothed Belt, Removing and Installing





Special tools, workshop equipment, test and measuring appliances and auxiliary items required
^ 2065 A Setting bar
^ V159 Pin wrench
^ 3359 Pin
^ VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.)

Removing
- Move lock carrier into service position [1][2]Procedures
- Remove ribbed belt.





- Press ribbed belt tensioning roller onto stop using box wrench in direction of arrow, then remove upper toothed belt guard.





- Turn crankshaft to TDC cyl. 1
^ Vehicles with manual transmission only





- Turn crankshaft to TDC cyl. 1
^ Vehicles with automatic transmission only
The slightly angled left edge of the sight hole is the reference mark. The edge must pass through the center of the 0.

Vehicles with manual transmission, engine removed





- Install adjustment device 2068 A as shown.
- Set adjusting tool to 107 mm. The reference point is the graduation mark on the left of the vernier scale -arrow-.
- Turn crankshaft until TDC mark on flywheel is aligned with tip of adjusting tool.

Vehicles with automatic transmission, engine removed





- Install 2068 A adjustment device as shown.
- Set adjusting tool to 99 mm. Reference point is graduation mark on left of vernier scale -arrow-.
- Turn crankshaft until TDC mark on flywheel is aligned with tip of adjusting tool.





- Lock camshaft with setting bar.
- Centralize setting bar as follows:
Turn camshaft so that one end of setting bar contacts the cylinder head. Using a feeler gauge measure the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder head.

- Remove idler roller.





- Lock injection pump sprocket with pin.
- Remove vibration damper and belt pulley.
- Remove lower toothed belt guard.
- Mark direction of engine rotation on toothed belt.
- Loosen tensioner.
- Take off toothed belt.

Installing
- Check whether TDC mark on flywheel and reference mark are aligned.
- Loosen camshaft sprocket mounting bolt a half turn.





- Place drift through hole in rear of toothed belt guard and release camshaft sprocket from camshaft taper with blow from hammer.
- Install idler roller.
- Install toothed belt (note direction of rotation) and remove pin from injection pump sprocket.





- Tension toothed belt. Using pin wrench (e.g. Matra V159) on eccentric turn it clockwise until notch and raised mark -arrows- align.
- Tighten mounting nut 20 Nm (15 ft. lbs.)
- Check TDC mark on flywheel again.
- Tighten camshaft sprocket mounting bolt 45 Nm (33 ft. lbs.)
- Remove 2065 A setting bar from camshaft and 3359 pin from injection pump sprocket.
- Turn crankshaft two rotations in direction of engine rotation and set again to cyl. 1 TDC.
- Install toothed belt guard, vibration damper, belt pulley, and valve cover.
- Install ribbed belt.
- Check injection pump "Start of delivery"